Ford E9SZ-2B120-A Brake Caliper

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To remove and overhaul the front brake calipers, start by applying the parking brake and blocking the rear wheels. Loosen the wheel lug nuts, raise the front of the vehicle, and support it on jackstands. Remove the wheel and unscrew the brake hose banjo bolt, detaching the hose from the caliper. Protect the hose end with a plastic bag to prevent fluid loss. If the caliper won't be completely removed, suspend it with wire, avoiding the need to bleed the brake system later. Proceed with the separation of the caliper from the spindle as part of the brake pad replacement procedure. For the overhaul, clean the caliper exterior with brake cleaner or denatured alcohol and place it on a clean workbench. Use compressed air to carefully remove the piston, ensuring it's cushioned and not blown out. Pull out the dust boot from the caliper bore and use a wood or plastic tool to remove the piston seal without causing bore damage. Examine the piston and caliper bore for defects, polishing the bore if needed. Remove the bleeder valve and rubber cap, inspect caliper locating pins and replace if corroded or damaged. Remove caliper locating pin insulators, clean all parts with brake fluid or denatured alcohol, and fit new insulators. Ensure the piston moves freely in the bore, then install the bleeder valve and cap. Lubricate the new piston seal and bore, fit the seal without twisting, and seat the dust boot properly. Lubricate the caliper piston, push it into the caliper using a turning motion, and then use a C-clamp and wood block to push the piston to the bore's bottom while ensuring it remains straight. Seat the dust boot's lip in the piston groove. Caliper installation, connect the brake hose with new sealing washers, and tighten the banjo bolt. Bleed the brakes if the banjo bolt was loosened, reinstall the wheel, lower the vehicle, and tighten the lug nuts before testing the brakes' operation before normal use.

Due to the relatively complex design of the rear brake caliper/parking brake actuator assembly, all service procedures requiring disassembly and reassembly should be left to a professional mechanic. The home mechanic can, however, remove the caliper and take it to a repair shop or Ford dealer service department for repair, thereby saving the cost of removal and installation. To remove the caliper, it is necessary to partially remove the caliper to remove the rear brake pads. Then, remove the lower slider pin pinch bolt. Disconnect the brake hose from the caliper. Wrap a plastic bag tightly around the end of the hose to prevent fluid loss and contamination. If the caliper is being removed for access to other components only, removing the hose won't be necessary. If this is the case, hang the caliper out of the way with a piece of wire. Lift the caliper away from the anchor plate. Installation is the reverse of the removal procedure. Ensure correct installation of the caliper over the brake pads. Finally, bleed the brakes.