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    Ford Taurus/Sable 1996-1999 Repair Guide

    Brake Caliper

    Print

    REMOVAL & INSTALLATION



    Front

    See Figures 1 and 2



    Click image to see an enlarged view

    Fig. Fig. 1: Remove the caliper locating pins and...



    Click image to see an enlarged view

    Fig. Fig. 2: ... remove the caliper from the bracket and rotor

    1. Remove brake fluid from the brake master cylinder reservoir until the reservoir is 1 / 2 full.
    2.  
    3. Raise and safely support the vehicle.
    4.  
    5. Remove the wheel and tire assembly.
    6.  
    7. Mark the disc brake caliper to ensure that it is reinstalled in the correct location.
    8.  
    9. Remove the hollow bolt connecting the brake hose to the disc brake caliper and plug the brake hose. Discard the 2 copper sealing washers.
    10.  


    WARNING
    Do not pry directly against the piston or damage to the piston will result.

    1. Remove the caliper locating pins and lift the caliper off the rotor using a rotating motion.
    2.  

    To install:
    1. Retract the disc brake caliper piston fully in the piston bore, using an old brake pad or block of wood and a C-clamp or equivalent.
    2.  

    Be sure to clean all dirt from the mating surfaces of the caliper locating pins and housing ears. Also, make sure the clip-on insulators are attached to the brake pads.

    1. Install the disc brake pads to the caliper. Make sure the brake pad insulators are correctly attached to the brake pad plate.
    2.  
    3. Position the disc brake caliper and pad assembly above the rotor and install it with a rotating motion. Make sure the inner and outer pads are properly positioned and the outer anti-rattle spring is properly positioned.
    4.  
    5. Lubricate the locating pins and the inside of the insulators with silicone grease. Tighten the locating pins to 23-28 ft. lbs. (31-38 Nm).
    6.  
    7. Remove the plug and install the brake hose to the disc brake caliper. Use 2 new copper washers and torque the hollow bolt to 30-40 ft. lbs. (41-54 Nm).
    8.  
    9. Bleed the brake system, filling the master cylinder as required.
    10.  
    11. Install the wheel and tire assembly; tighten the nuts to 85-104 ft. lbs. (115-142 Nm).
    12.  
    13. Lower the vehicle.
    14.  
    15. Pump the brake pedal several times to position the brake pads prior to moving the vehicle.
    16.  
    17. Road test the vehicle and check for proper brake system operation.
    18.  

    Rear

    See Figures 3 through 8



    Click image to see an enlarged view

    Fig. Fig. 3: Rear caliper brake hose connection



    Click image to see an enlarged view

    Fig. Fig. 4: Remove the retaining clip from the parking brake cable and...



    Click image to see an enlarged view

    Fig. Fig. 5: ... remove the cable from the caliper



    Click image to see an enlarged view

    Fig. Fig. 6: Remove the top and...



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    Fig. Fig. 7: ... lower caliper locating pins. The lower locating pin must be removed using a wrench to clear the parking brake actuator spring



    Click image to see an enlarged view

    Fig. Fig. 8: Carefully slide the caliper from the caliper bracket and off of the rotor

    1. Remove brake fluid from the brake master cylinder reservoir until the reservoir is 1 / 2 full.
    2.  
    3. Raise and safely support the vehicle.
    4.  
    5. Remove the wheel and tire assembly.
    6.  
    7. Remove the retaining bolt and disconnect the brake hose from the caliper assembly. Discard the copper sealing washers.
    8.  
    9. Remove the retaining clip from the parking brake at the caliper. Disengage the parking brake cable end from the lever arm.
    10.  
    11. Lift the rear disc brake caliper away from the rear disc support bracket.
    12.  
    13. Remove the disc brake caliper locating pins and boots from the rear disc support bracket.
    14.  

    To install:
    1. Using rear caliper piston adjuster tool T87P-2588-A or equivalent, rotate the rear disc brake piston and adjuster clockwise until fully seated.
    2.  

    Make sure one of the 2 slots in the rear disc brake piston and adjuster face is positioned so it will engage the nib on the disc brake pad.

    1. Apply silicone dielectric compound or equivalent, to the inside of the slider pin boots and the slider pins.
    2.  
    3. Position the slider pins and boots in the support bracket. Position the caliper assembly on the support bracket. Make sure the brake pads are installed correctly.
    4.  
    5. Remove the residue from the pin retainer threads and apply 1 drop of threadlock and sealer. Install the pin retainers and tighten to 23-25 ft. lbs. (31-35 Nm).
    6.  
    7. Attach the cable end to the parking brake lever. Install the cable retaining clip on the caliper assembly.
    8.  
    9. Using new washers, connect the brake flex hose to the caliper. Tighten the retaining bolt to 40 ft. lbs. (54 Nm).
    10.  
    11. Bleed the brake system, filling the master cylinder as required.
    12.  
    13. Install the wheel and tire assembly; tighten the nuts to 85-104 ft. lbs. (115-142 Nm).
    14.  
    15. Lower the vehicle.
    16.  
    17. Pump the brake pedal several times to position the brake pads prior to moving the vehicle.
    18.  
    19. Road test the vehicle and check for proper brake system operation.
    20.  

    OVERHAUL



    See Figures 9 through 16

    Some vehicles may be equipped dual piston calipers. The procedure to overhaul the caliper is essentially the same with the exception of multiple pistons, O-rings and dust boots.

    1. Remove the caliper from the vehicle and place on a clean workbench.
    2.  


    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!

    Depending upon the vehicle, there are two different ways to remove the piston from the caliper. Refer to the brake pad replacement procedure to make sure you have the correct procedure for your vehicle.

    1. The first method is as follows:
      1. Stuff a shop towel or a block of wood into the caliper to catch the piston.
      2.  
      3. Remove the caliper piston using compressed air applied into the caliper 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.
      4.  

    2.  



    Click image to see an enlarged view

    Fig. Fig. 9: For some types of calipers, 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. Fig. 10: Withdraw the piston from the caliper bore

      1. For the second method, you must rotate the piston to retract it from the caliper.
      2.  
      3. If equipped, remove the anti-rattle clip.
      4.  




    Click image to see an enlarged view

    Fig. Fig. 11: On some vehicles, you must remove the anti-rattle clip

    1. Use a prytool to remove the caliper boot, being careful not to scratch the housing bore.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 12: Use a prytool to carefully pry around the edge of the boot...



    Click image to see an enlarged view

    Fig. Fig. 13: ... then remove the boot from the caliper housing, taking care not to score or damage the bore

    1. Remove the piston seals from the groove in the caliper bore.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 14: Use extreme caution when removing the piston seal; DO NOT scratch the caliper bore

    1. Carefully loosen the brake bleeder valve cap and valve from the caliper housing.
    2.  
    3. Inspect the caliper bores, pistons and mounting threads for scoring or excessive wear.
    4.  
    5. Use crocus cloth to polish out light corrosion from the piston and bore.
    6.  
    7. Clean all parts with denatured alcohol and dry with compressed air.
    8.  

    To assemble:
    1. Lubricate and install the bleeder valve and cap.
    2.  
    3. Install the new seals into the caliper bore grooves, making sure they are not twisted.
    4.  
    5. Lubricate the piston bore.
    6.  
    7. Install the pistons and boots into the bores of the calipers and push to the bottom of the bores.
    8.  
    9. Use a suitable driving tool to seat the boots in the housing.
    10.  



    Click image to see an enlarged view

    Fig. Fig. 15: Use the proper size driving tool and a mallet to properly seal the boots in the caliper housing

    1. Install the caliper in the vehicle.
    2.  
    3. Install the wheel and tire assembly, then carefully lower the vehicle.
    4.  
    5. Properly bleed the brake system.
    6.  



    Click image to see an enlarged view

    Fig. Fig. 16: There are tools, such as this Mighty-Vac, available to assist in proper brake system bleeding

     
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