Rear Caliper Removal And Refitting; Rear Caliper Overhaul - Ford Scorpio Owner's Manual

10•6 Braking system
10.5 Removing the piston seal
5 Extract the piston seal from the groove in
the bore, using a blunt instrument (see
illustration). Discard the seal and dust boot.
6 Clean the piston and bore with methylated
spirit and inspect them for scuffs, scores or
other damage. If the piston is corroded it must
be renewed. Slight imperfections in the bore
can be polished out with wire wool.
7 Place the clean component on a clean
surface ready for reassembly. Lubricate the
caliper hose with clean hydraulic fluid.
8 Fit the new piston seal to the groove in the
bore, using fingers only to work it into position.
9 Lubricate the piston with clean hydraulic
fluid and fit the dust boot over the piston,
making sure it is the right way up. Insert the
piston into the bore and press it home,
engaging the dust boot lip with the groove on
the caliper (see illustration).
10 This completes the overhaul of the hydraulic
components. Items such as slide bolts and
bracket can also be renewed if necessary.
11 Remove the bleed screw while the caliper
is on the bench and apply a little anti-seize
compound to its threads, to avoid trouble in
undoing it later.
11 Rear caliper - removal and
refitting
1 With the ignition off, pump the brake pedal
at least 20 times (or until it becomes hard) to
depressurise the system.
2 Chock the front wheels and release the
handbrake. Slacken the rear wheel nuts, raise
12.4a Removing the circlip from a rear
caliper piston . . .
10.9 Pressing the piston into the bore
and support the vehicle and remove the
relevant wheel.
3 Disconnect the pad wear warning wires,
when fitted.
4 Disconnect the flexible hose from the brake
pipe. Plug or cap the open unions to reduce
spillage and to keep dirt out. Unscrew the
flexible hose from the caliper and remove it.
5 Remove the two slide bolts. Lift the caliper
off the pads and bracket, at the same time
unhooking the handbrake
illustrations). Alternatively, the two bracket-
to-hub bolts can be removed and the caliper
and bracket separated on the bench.
6 Refit by reversing the removal operations,
but before refitting the wheel, bleed both rear
calipers as described in Section 2.
7 When bleeding is complete, pump the brake
pedal several times to bring the pads up to the
disc, then check the operation of the
handbrake.
12 Rear caliper - overhaul
Note: Complete dismantling of the rear caliper
should not be attempted unless Ford spring
compressor (tool No 12-007) is available. or
unless the problems likely to arise in the absence
of the tool are understood. Renewal of the piston
seal and dust boot requires no special tools.
1 Clean the caliper externally and mount it in a
soft-jawed vice.
2 Rotate the piston anti-clockwise until it is
12.4b . . . followed by a thrustwasher . . .
11.5a Unhook the handbrake cable . . .
cable (see
11.5b . . . and remove the rear caliper
protruding from the bore by about 20 mm (0.8 in).
Free the dust boot from the groove in the
piston, then carry on unscrewing the piston
and remove it. Remove and discard the dust
boot.
3 The piston and bore may now be cleaned
and examined, and the piston seal and dust
boot renewed, as described for the front
caliper (Section 10).
4 The piston adjuster nut seal should also be
renewed. Remove the circlip from the piston,
then extract the thrustwashers, wave washer
and thrust bearing. Note the fitted sequence of
these components. Finally remove the nut
(see illustrations).
5 Remove the seal from the nut, noting which
way round it is fitted. Clean the nut with
methylated spirit. Lubricate the new seal with
clean hydraulic fluid and fit it to the nut.
12.4c . . . a wave washer and (not shown)
another thrustwasher . . .