Ford F8RZ-2552-AA
Caliper Assembly, Passenger Side

The brake caliper requires removal before any servicing or repairing operations begin. A block of wood or shop rags should be used to isolate the caliper piston from caliper housing due to safety reasons. Compressed air extraction provides the necessary tool to remove the caliper piston from the housing before proceeding with caliper piston removal. The service technician should inspect the caliper piston and piston bore for signs of pitting and scoring before renewing damaged parts. Start by lubricating the piston bore and piston seal and caliper piston with High Performance DOT 3 brake fluid C6AZ-9542-AB or any equivalent that complies with Ford specifications E5A-M6C25-A. After that place a new piston seal inside the machined groove of the piston bore and attach a new dust cap to the caliper piston. Be careful to avoid damaging the caliper piston when putting it into the caliper bore because you should lastly reinstall the caliper while properly seating the dust cap.

A block of wood or shop rags should go between the caliper piston and the caliper housing before its removal for brake caliper service. Compressed air extraction will remove the caliper piston from the housing before you discard the dust seal and piston seal. Inspection of both the caliper piston and piston bore must happen before replacement of the piston when pitting or scoring appears. Lubricate the piston bore and caliper piston together with High Performance Dot 3 Brake Fluid C6AZ-19542-AB or a Dot 3 equivalent following Ford specifications ESA-M6C25-A. Afterwards, install a new piston seal in the grooved piston bore and secure a new dust seal onto the caliper piston. Put the caliper piston into the caliper bore while avoiding damage to both components then insert the dust seal before installing the caliper assembly.

Starting brake caliper maintenance requires a worker to first loosen wheel nuts then secure a raised vehicle while removing the wheel. Service the brake caliper by disconnecting it with multiple steps starting with removal of the pad clip then brake hose union followed by removal of bolt covers and bolts. Unscrew the brake pads and protect the brake hose connection by using caps to stop fluid loss while avoiding dirt entry before removing the brake caliper from its hose. The installation process requires lowering the caliper piston to maximum retraction level and adding the brake hose loosely to the caliper before brake pad placement begins with the inner pad followed by the outer pad. Secure the caliper through tightening its bolts then place bolt covers and attach the brake pad clip to complete the operation. Finish off by securing the brake hose union. The wheel should then be installed with a brake system bleeding procedure to finish the installation.

Place a block of wood or shop rags between the caliper piston and the caliper housing.

Install a new dust seal onto the caliper piston.

Install the inner brake pad first, followed by the outer brake pad.

Disconnect the brake pad wear sensor electrical connector if equipped.