Aerostar 2WD V6-245 4.0L (1990)
Brake Caliper: Service and Repair
Overhaul
1.
Remove caliper and linings.
2.
Drain brake fluid from caliper housing, then position housing in a vise.
3.
Pad area between piston(s) and caliper bridge, then apply compressed air to caliper fluid port to remove piston(s). If piston is seized and cannot be
forced from caliper, tap lightly around cylinder bore area while applying air pressure. Use caution when applying air pressure, as piston(s) may
develop considerable force from pressure build-up.
4.
Remove and discard molded rubber boot(s) and square cut seal(s) from caliper assembly.
5.
Thoroughly clean piston(s) and caliper assembly using a suitable cleaner, then dry grooves and passageways with compressed air.
6.
Check piston(s) and cylinder bore(s) for damage or excessive wear and replace as necessary.
7.
Lubricate new piston seal(s) and cylinder bore(s) with clean brake fluid, then install seal(s) in cylinder bore groove(s).
8.
Lubricate dust boot retaining lip with clean brake fluid, then install boot lip in cylinder bore groove.
9.
Lubricate piston with clean brake fluid, then insert piston through dust boot and into cylinder bore past the piston seal. Use a block of wood to
press piston to bottom of cylinder bore.
10.
On dual piston calipers, repeat procedure for other piston and boot.
11.
On all calipers, install caliper and linings
