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Rear Brake Caliper: 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.
NOTE: Dual piston calipers shown, single piston caliper similar.
  1. Remove the rear disc brake caliper. For additional information, refer to BRAKE CALIPER - E-150  or BRAKE CALIPER - E-250, E-350 .
  2. Drain the remaining brake fluid from the disc brake caliper.
  3. Apply low air pressure to the fluid port in the disc brake caliper.
    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 rear disc brake calipers and force out the caliper pistons to the block of wood.
    3. Remove the block of wood and the caliper pistons.
      Fig 1: Removing Block Of Wood And Caliper Pistons
      G03884744Courtesy of FORD MOTOR CO.
  4. Remove the piston seals and boots.
    1. Remove the piston boot retainer.
    2. Remove and discard the piston boots and seals.
      Fig 2: Removing Piston Boots And Seals
      G03884745Courtesy of FORD MOTOR CO.
    5. NOTE: Do not hone the caliper bores. Pistons are not available for honed caliper bores.
  5. If the caliper bores are excessively scored or corroded, install a new disc brake caliper.
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