All about Ford Mondeo

Front brake caliper - removal, overhaul and refitting
Braking system / Front brake caliper - removal, overhaul and refitting


Note: Refer to the warning at the beginning of the previous Section before proceeding.

Removal
1 Apply the handbrake. Loosen the front wheel nuts, jack up the front of the vehicle and support it on axle stands. Remove the appropriate front wheel.

2 Fit a brake hose clamp to the flexible hose leading to the front brake caliper. This will minimise brake fluid loss during subsequent operations (see illustration).

3.2 Brake hose clamp fitted to the front flexible brake hose
3.2 Brake hose clamp fitted to the front flexible brake hose

3 Loosen (but do not completely unscrew) the union on the caliper end of the flexible brake hose (see illustration).

3.3 Loosening the flexible brake hose at the caliper
3.3 Loosening the flexible brake hose at the caliper

4 Remove the front brake pads as described in Section 2.

5 Support the caliper in one hand, and prevent the hydraulic hose from turning with the other hand. Unscrew the caliper from the hose, making sure that the hose is not twisted unduly or strained. Once the caliper is detached, plug the open hydraulic unions in the caliper and hose, to keep out dust and dirt.

6 If required, the caliper carrier bracket can be unbolted and removed from the steering knuckle (see illustration).

3.6 Removing the caliper carrier bracket
3.6 Removing the caliper carrier bracket

Overhaul
7 With the caliper on the bench, brush away all traces of dust and dirt, but take care not to inhale any dust, as it may be injurious to health.

8 Pull the dust-excluding rubber seal from the end of the piston.

9 Apply low air pressure to the fluid inlet union, and eject the piston. Only low air pressure is required for this, such as is produced by a foot-operated tyre pump.

Caution: The piston may be ejected with some force.

10 Using a suitable blunt instrument (for instance a knitting needle or a crochet hook), prise the piston seal from the groove in the cylinder bore. Take care not to scratch the surface of the bore.

11 Clean the piston and caliper body with methylated spirit, and allow to dry. Examine the surfaces of the piston and cylinder bore for wear, damage and corrosion. If the piston alone is unserviceable, a new piston must be obtained, along with seals. If the cylinder bore is unserviceable, the complete caliper must be renewed. The seals must be renewed, regardless of the condition of the other components.

12 Coat the piston and seals with clean brake fluid, then manipulate the piston seal into the groove in the cylinder bore.

13 Push the piston squarely into its bore.

14 Fit the dust-excluding rubber seal onto the piston and caliper, then depress the piston fully.

Refitting
15 Refit the caliper, and where applicable the carrier bracket, by reversing the removal operations. Make sure that the flexible brake hose is not twisted. Tighten the mounting bolts and wheel nuts to the specified torque (see illustration).

3.15 Tightening the carrier bracket mounting bolts
3.15 Tightening the carrier bracket mounting bolts

16 Bleed the brake circuit according to the procedure given in Section 15, remembering to remove the brake hose clamp from the flexible hose. Make sure there are no leaks from the hose connections. Test the brakes carefully before returning the vehicle to normal service.


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