Lincoln Corsair: Front Disc Brake / Removal and Installation - Brake Caliper

Materials

Removal

  WARNING: Service actions on vehicles equipped with electronic brake booster and electronic parking brakes may cause unexpected brake application, which could result in injury to hands or fingers. Put the brake system into service mode prior to servicing or removing any brake components. Failure to follow this instruction may result in serious personal injury.

NOTICE: Make sure that all openings are sealed.

NOTICE: If the brake fluid is spilled on any component, the affected area must be immediately washed down with cold water.

NOTE: Removal steps in this procedure may contain installation details.

1. Activate the brake service mode.
   Refer to: Brake Service Mode Activation and Deactivation (206-00 Brake System - General Information, General Procedures).
   

1. Remove the wheel and tire.
   Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
   

1. Remove the brake caliper spring.
   

1. NOTICE: Make sure that all openings are sealed.

   NOTICE: Take extra care not to damage the mating faces.

   NOTICE: Make sure that the brake hose is not twisted and is correctly located.

   Remove the bolt and disconnect the brake hose. Discard the washers.
   Torque: 30 lb.ft (40 Nm)

1. Remove the caps.
   

1. NOTICE: Do not pry in the caliper sight hole to retract the pistons as this can damage the pistons and boots.

   Remove the brake caliper guide pin bolts and the brake caliper.
   Torque: 21 lb.ft (28 Nm)

Vehicles without adhesive on brake pad insulator

1. Remove the brake pads.
   

Vehicles with adhesive on brake pad insulator

1. NOTICE: Brake pads with adhesive on the insulator are one-time use only. When the brake pads are separated from the brake caliper, new brake pads must be installed to prevent brake noise and shudder.

   NOTICE: When installing the new brake pads make sure to remove the foil backing from the outboard brake pads. Once the foil backing is removed from the brake pads do not touch the adhesive on the backing.

   Separate the outboard brake pad from the brake caliper. Discard the brake pad.
   

1. NOTICE: Brake pads with adhesive on the insulator are one-time use only. When the brake pads are separated from the brake caliper, new brake pads must be installed to prevent brake noise and shudder.

   NOTICE: When installing the new brake pads make sure to remove the foil backing from the outboard brake pads. Once the foil backing is removed from the brake pads do not touch the adhesive on the backing.

   Separate the inboard brake pad from the brake caliper. Discard the brake pad.
   

All vehicles

1. NOTICE: Protect the caliper pistons and boots when pushing the caliper piston into the caliper piston bores or damage to components may occur.

   Use a C-clamp and a worn brake pad to compress the disc brake caliper pistons into the brake caliper bore.
   

Installation

1. To install, reverse the removal procedure.
   

1. Apply the specified grease.
   Material: Motorcraft® Silicone Brake Caliper Grease and Dielectric Compound / XG-3-A (ESA-M1C200-A) (ESE-M1C171-A)

Vehicles with adhesive on brake pad insulator

NOTICE: When installing the new brake pads make sure to remove the foil backing from the outboard brake pads. Once the foil backing is removed from the brake pads do not touch the adhesive on the backing.

1. Clean all residual pad adhesive from the finger area of the brake caliper. Make sure the finger area is free of grease and foreign material.
   Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B, APM-4-C

1. Clean all residual pad adhesive from the piston area of the brake caliper. Make sure the piston area is free of grease and foreign material.
   Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B, APM-4-C

All vehicles

1. Deactivate the brake service mode.
   Refer to: Brake Service Mode Activation and Deactivation (206-00 Brake System - General Information, General Procedures).
   

1. Bleed the brake system.
   Refer to: Brake System Pressure Bleeding (206-00 Brake System - General Information, General Procedures).
   

1. Start the engine and apply the brake pedal firmly 5 times to assure the outboard brake pads are bonded to the caliper.