Aerostar 2WD V6-245 4.0L (1990)
Brake Caliper: Service and Repair
Rail Slider Caliper
REMOVAL
1.
Drain a small amount of brake fluid from master cylinder reservoir.
2.
Raise and support vehicle, then remove wheel and tire assembly.
3.
Install an eight inch C-clamp on caliper housing and tighten clamp to bottom piston(s) in cylinder bore(s), then remove clamp. Do not use
screwdriver or other edged tool to pry piston(s) from rotor.
4.
Remove key retaining screw, then using a hammer and drift, drive out caliper support key and spring.
5.
On single piston calipers, push caliper downward against spindle, then rotate upper end upward and out of spindle assembly.
6.
On dual piston calipers, rotate key and spring end of caliper out and away from rotor, then slide opposite end of caliper clear of mount and off
the rotor.
7.
On all calipers, disconnect hydraulic line from caliper only if caliper service is required. If not being removed for service, properly support
caliper.
8.
On single piston calipers, remove outer brake pad by tapping to loosen pad flange, then the inner pad and the anti-rattle clip.
9.
On dual piston calipers, remove anti-rattle spring and brake pads.
INSTALLATION
1.
On single piston calipers, proceed as follows:
a.
Place new anti-rattle clip on lower end of inner brake pad. Ensure tabs on clip are properly positioned and the clip is fully seated.
b.
Place inner pad and anti-rattle clip in shoe abutment with anti-rattle clip tab against shoe abutment and looped spring away from rotor, then
compress anti-rattle clip and slide upper end of pad into position.
c.
Ensure piston is bottomed in caliper cylinder bore. Position outer brake pad on caliper and press pad tabs into place.
d.
Position caliper on spindle assembly by pivoting caliper around support upper mounting surface. Use caution not to tear or cut boot when
positioning caliper over inner brake pad.
2.
On dual piston calipers, proceed as follows:
a.
Place used inner brake pad over pistons, then place a C-clamp on the caliper housing midway between two pistons and over the brake pad.
Tighten clamp until pistons are bottomed in caliper, then remove C-clamp and used brake pad.
b.
Install new brake pads and anti-rattle spring.
c.
Position caliper rail into slide on support and rotate caliper onto rotor.
3.
On all calipers, using brake adjusting tool or screwdriver, hold upper machined surface of caliper against surface of support assembly and install
new caliper support spring and new caliper support key.
4.
Using suitable mallet, drive key and spring assembly into position, then install key retaining screw and torque to specification.
5.
If removed, connect hydraulic line to caliper.
6.
If hydraulic system was opened during repair procedure, bleed the brakes as described in BRAKE BLEEDING.
7.
Install wheel and tire assemblies.
8.
Lower vehicle, check brake fluid level and replenish as necessary, then ensure proper operation of brakes.
