Complete disassembly, cleaning, inspection, and rebuild of front brake calipers using rebuild kits, including piston replacement, seal installation, and proper lubrication.

Warnings

Tools required

Parts

• Front brake caliper rebuild kit (per side) × 2 — Use OEM specification or quality aftermarket
• Silicone brake grease (high-temp) × 1 — Motorcraft or equivalent
• Threadlocker (medium strength) × 1 — Loctite 243 or equivalent
• Shop towels (lint-free) × 1 — Generic

Fluids

• Motorcraft DOT 4 LV Brake Fluid — 1 qt

Preparation

1. Park vehicle on level, solid ground and engage parking brake
2. Remove approximately half the brake fluid from master cylinder reservoir using turkey baster or fluid extractor to prevent overflow during piston compression
3. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
4. Raise front of vehicle with floor jack and secure on jack stands rated for vehicle weight
5. Remove front wheels completely
6. Verify you have correct rebuild kits for your specific caliper type (may vary by brake package)
7. Organize workspace with clean area for caliper disassembly and parts inspection

Procedure

1. 1

   Remove caliper from vehicle
   Place drain pan under caliper. Using appropriate socket, remove the two caliper slide pin bolts that attach the caliper to the bracket. Support the caliper, then carefully disconnect the brake hose banjo bolt. Immediately plug the brake hose opening with a clean rubber cap or tape to prevent fluid loss and contamination. Remove caliper from vehicle and place on clean workspace covered with shop towels.
   ⚠Brake fluid will drain when hose is disconnected. Position drain pan to catch all fluid.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
2. 2

   Remove brake pads and hardware
   Remove brake pads from caliper bracket. Remove any anti-rattle clips, shims, or hardware attached to the pads. Inspect the caliper bracket slide pins for wear or damage. Clean the bracket thoroughly with brake parts cleaner and wire brush, removing all rust and debris from slide pin bores.
3. 3

   Disassemble caliper body
   Place caliper on clean workspace with piston facing up. If compressed air is available, use very low pressure (10-20 PSI) against the brake hose port to gently push the piston out. Alternatively, use a large pair of pliers to carefully pull the piston out by hand. Once piston is removed, use plastic pick to carefully extract the piston dust boot from its groove in the caliper bore. Remove the piston seal from the internal groove using plastic pick—DO NOT use metal tools as they will scratch the bore.
   ⚠️If using compressed air, use VERY LOW pressure and control piston movement. High pressure can cause piston to eject violently causing injury. Keep fingers clear of piston path.
   ⚠Never use metal tools inside caliper bore. Any scratches or damage to the bore will cause leaks and caliper failure.
4. 4

   Clean and inspect caliper bore
   Thoroughly clean the caliper bore using brake parts cleaner and lint-free shop towels. Inspect bore surface for any pitting, scoring, rust, or corrosion. The bore must be smooth and shiny. Light surface rust can be carefully removed with crocus cloth (very fine abrasive), but any significant corrosion, pitting, or scoring means the caliper must be replaced—do not attempt to rebuild. Check that all fluid passages are clear by spraying brake cleaner through them.
   ⚠If caliper bore shows ANY pitting, deep scratches, or corrosion that cannot be polished smooth, REPLACE the caliper. A damaged bore will leak and cause brake failure.
5. 5

   Inspect piston and rebuild kit components
   Inspect the piston for damage, scoring, or corrosion. The piston surface must be perfectly smooth—replace if any damage is present. Unpack the rebuild kit and identify all components: new piston seals, dust boots, and any additional hardware. Verify the seals and boots match the originals in size and shape. Clean the new piston (if included in kit) with brake parts cleaner.
6. 6

   Install new piston seal
   Dip the new piston seal in clean DOT 4 LV brake fluid. Carefully install the seal into the internal groove of the caliper bore using only your fingers. Ensure the seal seats completely and evenly in the groove with no twists or folds. The seal should sit flat and smooth in its groove all the way around.
   ⚠Do not use tools to install the seal as this can damage it. Only use clean brake fluid as lubricant—never use petroleum-based products.
7. 7

   Install piston and dust boot
   Lubricate the piston and caliper bore liberally with clean DOT 4 LV brake fluid. Install the dust boot onto the piston first, seating it in the piston groove. Carefully insert the piston into the caliper bore at a slight angle, then straighten as it enters. Push piston in slowly and squarely—it should slide smoothly without force. Once piston is bottomed in bore, seat the outer edge of the dust boot into the caliper body groove, ensuring it's properly seated all the way around.
   ⚠Piston must enter bore squarely to avoid damaging the seal. If resistance is felt, remove piston and check for seal damage or misalignment.
8. 8

   Service caliper bracket and slides
   Remove caliper slide pins from bracket if not already removed. Clean slide pins thoroughly with brake parts cleaner and inspect for wear, corrosion, or damage. Clean the slide pin bores in the bracket. Apply a thin coat of silicone brake grease to the slide pins (not the threads) and reinstall into bracket. Slide pins should move smoothly in their bores. Clean all mating surfaces where caliper mounts to bracket.
9. 9

   Reinstall caliper to vehicle
   Install new brake pads and hardware into caliper bracket if removed. Position rebuilt caliper over rotor and bracket. Remove plug from brake hose and install new copper washers (included in rebuild kit) on both sides of banjo bolt. Connect brake hose to caliper and hand-tighten banjo bolt. Apply silicone brake grease to caliper slide pin bolt threads and sliding surfaces. Install slide pin bolts and torque to specification.
   ℹ️Always use NEW copper crush washers on banjo bolt. Reusing old washers will cause leaks.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
10. 10

    Bleed brake caliper
    Attach clear plastic tubing to bleeder screw and place other end in catch bottle partially filled with brake fluid. Have assistant pump brake pedal 3-5 times and hold pressure, or use vacuum bleeder per tool instructions. Open bleeder screw 1/4 to 1/2 turn while pressure is applied. Close bleeder screw before pedal reaches floor (if using assistant). Repeat until fluid flows clear with no air bubbles. Torque bleeder screw to specification when complete. Top off master cylinder reservoir with fresh DOT 4 LV brake fluid.
    ⚠️Never let master cylinder run dry during bleeding or air will enter the ABS system requiring special bleeding procedures.
    ⚠Bleeder screw is brass and easily damaged. Use correct size wrench and do not overtighten.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
11. 11

    Repeat for opposite side
    Complete the entire rebuild procedure (steps 1-10) for the opposite front caliper. Work methodically and ensure all components are properly installed and torqued. Bleed the second caliper using the same procedure. Check master cylinder fluid level and top off as needed with fresh DOT 4 LV brake fluid.
12. 12

    Final brake system bleeding
    After both calipers are rebuilt and individually bled, perform a final system bleed starting with the wheel furthest from the master cylinder (right rear, left rear, right front, left front). Verify firm brake pedal with no sponginess. Check all connections for leaks while assistant applies brake pressure. Top off master cylinder to MAX line with fresh brake fluid.
    ⚠️Brake pedal must be firm before operating vehicle. A soft or spongy pedal indicates air in the system—continue bleeding until pedal is firm.
13. 13

    Reinstall wheels and perform final checks
    Reinstall wheels and hand-tighten lug nuts in star pattern. Lower vehicle to ground and torque lug nuts to specification in star pattern. Pump brake pedal several times to verify proper pedal feel. Inspect all brake connections for leaks. Check brake fluid level one final time.
    ⚠️Do NOT drive vehicle until brake pedal is verified firm and all leak checks are complete.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Ensure all caliper slide pins move freely and are properly lubricated with silicone brake grease
2. Verify all torque specifications were followed exactly—brake system components must be torqued correctly
3. Confirm brake hose banjo bolts have new copper crush washers installed
4. Double-check that dust boots are properly seated in both piston and caliper body grooves
5. Verify no brake fluid leaks are present at any connection point

Verification

• Start engine and pump brake pedal—pedal should be firm and high, with consistent feel
• With engine running, apply firm brake pressure and hold for 30 seconds—pedal should not sink
• Visually inspect all caliper connections, brake hoses, and bleeder screws for any signs of leakage
• Perform low-speed test drive in safe area (parking lot) to verify brakes engage smoothly and evenly with no pulling to either side
• After test drive, recheck all connections for leaks and verify brake fluid level
• Perform several moderate brake applications from 30-40 mph to seat pads and verify proper operation
• Road test at various speeds confirming normal brake operation, no noise, vibration, or pulling
• After first 50-100 miles, recheck caliper slide pin bolts for proper torque and inspect for any fluid leaks

More procedures for this vehicle