Rear Brake Caliper

WARNING: This page is about a different car, the 2004 Mercury Monterey and 2004 Ford Freestar. However, it is still accessible from the selected car via links, so may be relevant.

WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury.

WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury.

CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.

CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding operation. Keep the brake master cylinder reservoir filled with the DOT 3 motor vehicle brake fluid. Never reuse the brake fluid that has been drained from the hydraulic system.

NOTE: When any part of the hydraulic system has been disconnected for repair or installation of new components, air can get into the system and cause spongy brake pedal action. This requires bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can be bled manually or with pressure bleeding equipment.

NOTE: Due to the complexity of the fluid path within the rear integral parking brake calipers, it may be necessary to follow this procedure when new calipers are installed.

NOTE: This procedure is necessary only when installing a new rear brake caliper. To bleed the brake system, refer to BRAKE SYSTEM BLEEDING .

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
Remove the 2 brake caliper bolts and position the brake caliper aside.

Fig 1: Removing Brake Caliper Bolts
Courtesy of FORD MOTOR CO.
Remove the outer brake pad.

Fig 2: Removing Outer Brake Pad
Courtesy of FORD MOTOR CO.

NOTE: Place a shop towel between the caliper and the brake disc.

Install the brake caliper using the 2 brake caliper bolts.
- Tighten to 33 Nm (24 lb-ft).
  
  Fig 3: Installing Brake Caliper
  Courtesy of FORD MOTOR CO.
Slowly apply the brake pedal to extend the brake caliper piston out.
Remove the 2 brake caliper bolts and position the brake caliper aside.

Fig 4: Removing Brake Caliper Bolts
Courtesy of FORD MOTOR CO.
Bleed the brake caliper.
- Remove the bleeder screw cap and place a box end wrench on the brake caliper bleeder screw. Attach a rubber drain tube to the brake caliper bleeder screw and submerge the free end of the tube in a container partially filled with clean brake fluid.
  
  Fig 5: Bleeding Brake Caliper
  Courtesy of FORD MOTOR CO.
Loosen the brake caliper bleeder screw.
Using the special tool, fully retract the brake caliper piston and tighten the bleeder screw.
- Tighten to 10 Nm (7 lb-ft).
- Refill the brake master cylinder reservoir as necessary.
  
  Fig 6: Retracting Brake Caliper Piston
  Courtesy of FORD MOTOR CO.
Repeat steps 5 through 9 until clear, bubble free fluid comes out.
- Install the bleeder screw cap.
Install the outer brake pad.

Fig 7: Installing Outer Brake Pad
Courtesy of FORD MOTOR CO.
Position the brake caliper and install the 2 brake caliper bolts.
- Tighten to 33 Nm (24 lb-ft).
  
  Fig 8: Positioning Brake Caliper
  Courtesy of FORD MOTOR CO.