Expedition 4WD V8-5.4L SOHC VIN 5 (2005)
4. Remove the block of wood and the caliper pistons.
5. Remove and discard the piston seals and boots.
6. NOTE: Do not hone the cylinder bores. Pistons are not available for honed cylinder bores.
If the cylinder bores are excessively scored or corroded, replace the disc brake caliper.
Assembly
CAUTION: Never reuse piston seals and dust boots.
NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been allowed to stand in an open container for an extended
period of time.
1. Lubricate the piston boot, caliper piston, piston seal, and cylinder bores with brake fluid.
2. Place the brake caliper in a vise.
3. Install the caliper pistons.
1. Install the piston seal.
2. Install the piston boot on the brake caliper.
3. CAUTION: Be careful not to damage or dislodge the piston seal.
Insert the caliper piston.
4. CAUTION: Be careful not to cock the caliper piston.
Insert the piston into the disc brake caliper bore.
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Place the piston squarely against the dust boot.
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While applying shop air to the fluid port in the disc brake caliper, push the piston squarely into the bore.
