Front Brake Caliper - E-250, E-350, E-450: Disassembly

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Remove the disc brake caliper (2B120). For additional information, refer to BRAKE CALIPER .
Drain remaining brake fluid from the disc brake caliper.
Secure the disc brake caliper in a vise.
Remove the caliper pistons.
1. Place a block of wood between the caliper bridge and the caliper pistons.
2. Apply low air pressure to the fluid port in the disc brake caliper.
3. Force out the caliper pistons to the block of wood.
4. Remove the block of wood and the caliper piston.
  
  Fig 1: Removing Block Of Wood And Caliper Piston
  Courtesy of FORD MOTOR CO.
Remove and discard the piston seals and boots.

Fig 2: Removing Piston Seals And Boots
Courtesy of FORD MOTOR CO.

NOTE: Do not hone the caliper bores. Pistons are not available for honed caliper bores.

If the disc brake caliper is leaking, install new piston seals. If the caliper bores are excessively scored or corroded, install a new disc brake caliper.