Fusion L4-2.3L VIN Z (2006)
Removal
WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will
render the brakes inoperative. Failure to follow these instructions may result in personal injury.
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If
brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink
water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with
water.
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.
2. Disconnect the parking brake cable from the brake caliper.
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Pull back the parking brake lever.
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Disconnect the cable from the parking brake lever.
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Remove the cable conduit retaining clip.
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Disconnect the cable from the brake caliper.
3. Remove the brake caliper flow bolt and position the brake hose aside.
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Discard the 2 copper washers.
4. Remove the 2 brake caliper guide bolts and the brake caliper.
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If a leaking or damaged caliper piston boot is found, install a new disc brake caliper.
Installation
1. NOTE: Position the notch in the caliper piston so that it will correctly align with the pin on the backside of the inboard brake pad.
Install the brake caliper.
2. Install the 2 brake caliper guide bolts.
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To install, tighten to 26 Nm (19 ft. lbs.).
3. Using 2 new copper washers, position the brake hose and install the brake caliper flow bolt.
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Tighten to 25 Nm (18 ft. lbs.).
4. Install the parking brake cable to the brake caliper.
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Pull back the parking brake lever.
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Connect the cable to the parking brake lever.
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Install the cable conduit retaining clip.
5. Bleed the brake system.
6. Cycle the park brake several times to verify normal operation.
7. Test the brakes for normal operation.
