Quest 1995-1996

Brake Calipers

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Overhaul



Specific to:

Mercury Villager 1993-2000

Nissan Quest 1993-2000

  1. Remove the caliper from the vehicle and place on a clean workbench.
  2.  
  3. Open the bleeder screw and drain any remaining brake fluid from the caliper. Close the bleeder screw.
  4.  
  5. Stuff a shop towel or a block of wood into the caliper to catch the piston.
    CAUTION
    NEVER place your fingers in front of the pistons in an attempt to catch or protect the pistons when applying compressed air. This could result in personal injury!

  6.  
  7. Remove the caliper piston using compressed air applied into the brake hose inlet hole. Inspect the piston for scoring, nicks, corrosion and/or worn or damaged chrome plating. The piston must be replaced if any of these conditions are found.

    Click image to see an enlarged view

    Fig. Use compressed air to drive the piston out of the caliper, but make sure to keep your fingers clear



    Click image to see an enlarged view

    Fig. Withdraw the piston from the caliper bore

  8.  
  9. Use a prytool to remove the caliper boot, being careful not to scratch the housing bore.

    Click image to see an enlarged view

    Fig. Use a prytool to carefully pry around the edge of the boot . . .



    Click image to see an enlarged view

    Fig. . . . then remove the boot from the caliper housing, taking care not to score or damage the bore

  10.  
  11. Remove the piston seal from the groove in the caliper bore.

    Click image to see an enlarged view

    Fig. Use extreme caution when removing the piston seal; DO NOT scratch the caliper bore

  12.  
  13. Remove the bleeder screw from the caliper.
  14.  
  15. Inspect the caliper bores, pistons, and mounting threads for scoring or excessive wear.
  16.  
  17. Use crocus cloth to polish out light corrosion from the piston and bore.
  18.  
  19. Clean all parts with denatured alcohol and dry with compressed air.
  20.  

To assemble:

  1. Install the bleeder screw in the caliper.
  2.  
  3. Lubricate the new seal with new brake fluid and install it into the piston bore groove, making sure it is not twisted.
  4.  
  5. Lubricate the piston bore with new brake fluid.
  6.  
  7. Install the new boot on the piston.
  8.  
  9. Install the piston into the bore of the caliper and push it to the bottom of the bore.
  10.  
  11. Use a suitable driving tool to seat the boot in the caliper.

    Click image to see an enlarged view

    Fig. Use the proper size driving tool and a mallet to properly seat the boot in the caliper

  12.  
  13. Install the caliper in the vehicle.
  14.  
  15. Install the wheel and tire assembly, then carefully lower the vehicle.
  16.  
  17. Properly bleed the brake system.
  18.  

Removal & Installation



Specific to:

Mercury Villager 1993-2000

Nissan Quest 1993-2000


WARNING
Clean, high quality brake fluid is essential to the safe and proper operation of the brake system. You should always buy the highest quality brake fluid that is available. If the brake fluid becomes contaminated, drain and flush the system, then refill the master cylinder with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint.


CAUTION
Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance.


NOTE
If both calipers are being removed from the vehicle at the same time, mark them -left- and -right- so that they can be reinstalled in their original locations. The bleeder screws must be positioned on the top of the calipers when installed on the vehicle.

  1. Loosen the lug nuts on the front wheels.
  2.  
  3. Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle securely on jackstands.
  4.  
  5. Remove the front wheels.
  6.  
  7. Disconnect the brake flex hose from the caliper by removing the banjo bolt and copper washer. Discard the washer.
  8.  
  9. Using a Torx ® T-40 bit, remove the two caliper bolts.
  10.  
  11. Lift the caliper and brake pad assembly from the rotor using a rotating motion.
  12.  

To install:

  1. Make sure that the caliper piston is fully seated. If not, use a large C-clamp placed on a used inboard brake pad or wood block to compress the caliper piston.
  2.  
  3. Install the inboard pad in the caliper piston. Install the outboard pad, making sure that the clips are properly seated.
  4.  
  5. Position the caliper on the rotor.
  6.  
  7. Lubricate the caliper bolts with a silicone dielectric compound such as Ford D7AZ-19A331-A or equivalent silicone grease. Install the two caliper bolts and tighten them to 18 - 25 ft. lbs. (24 - 34 Nm).
  8.  
  9. Install the brake flex hose using a new copper washer. Tighten the banjo bolt to 30 - 45 ft. lbs. (40 - 60 Nm).
  10.  
  11. Fill the master cylinder reservoir, as necessary, using only new DOT 3 or equivalent brake fluid.
  12.  
  13. Properly bleed the brake system. Please refer to Bleeding the Brake System for the procedure.
  14.  
  15. Install the wheels. Tighten the lug nuts to 72 - 87 ft. lbs. (98 - 118 Nm).
  16.  
  17. Pump the brake pedal several times prior to moving the vehicle to position the brake pads to the rotor.
  18.  
  19. Refill the master cylinder reservoir as necessary, using only new DOT 3 or equivalent brake fluid.
  20.  
  21. Road test the vehicle and check the brake system for proper operation.
  22.  

 
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