Ford Mustang (1999-2004) Service Manual: Caliper (Disassembly and Assembly)

Special Tool(s)

Rear Caliper Piston Adjuster 206-026 (T87P-2588-A)
Rear Caliper Spring Compressor Set 206-S027 (T87P-2588-B)

Disassembly

1. Remove the rear disc brake caliper (2552). For additional information, refer to Caliper in the Removal and Installation portion of this section.

2. Drain the brake fluid from the rear disc brake caliper.

3. Secure the rear disc brake caliper in a vise.

4. Turn the rear disc brake piston and adjuster (2B588) counterclockwise with Rear Caliper Piston Adjuster.

Caliper

5. Remove the rear disc brake piston and adjuster from the caliper bore.

Caliper

6. Remove and discard the piston dust boot seal and piston seal from the caliper bore.

7. CAUTION: The parking brake lever pin retainer clip (2A746) and spring cover are spring-loaded. Use care when removing the parking brake lever pin retainer clip.

Remove the parking brake lever pin retainer clip.

  • Unload the spring tension from the parking brake lever pin retainer clip and spring cover using Screw and Cross Block, a 6-mm washer head nut and a 1/2-inch drive 14-mm socket.
  • Remove the parking brake lever pin retainer clip with suitable snap-ring pliers.
  • Remove Screw and Cross Block.

Caliper

8. Remove the following components:

1. spring cover

2. spring

3. washer

4. key plate

5. push rod

6. strut pin

7. push rod O-ring

Caliper

9. Remove and discard the O-ring seal from the push rod.

10. Remove the parking brake lever (2A637).

1. Remove the parking brake return spring (2456).

2. Remove the limiting bolt (2A795).

3. Remove the parking brake lever.

4. Remove the parking brake lever shaft seal from the caliper bore.

Caliper

Assembly

1. CAUTION: Do not reuse piston seals or dust boots. Install new seals or dust boots or damage to the vehicle can occur.

NOTE: Use new brake fluid when assembling and bleeding the brake system.

NOTE: Lightly lubricate the parking brake lever bore, limiting bolt, parking brake lever shaft and parking brake shaft recess with Silicone Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A.

Follow the disassembly procedure in reverse order.

 

    Shield
    Removal 1. Remove the brake disc (2C026). For additional information, refer to Disc in this section. 2. Remove the brake disc shield bolts. Installation 1. Follow the removal procedure in r ...

    Parking Brake and Actuation
    Torque Specifications ...

    Other materials:

    Safety Belt Tongue Rotated on Belt
    1. Grasp the belt tongue and pull the belt webbing down to form a loop through the upper (longer and narrower) slot in the tongue. 2. Rotate and fold the belt webbing over itself within the slot to remove the twist. 3. Pull the excess belt webbing back th ...

    Switch - Horn
    Removal 1. Remove the driver side air bag module (043B13). Refer to Section. 2. Remove the switches. 1. Disconnect the horn wire from the switches. 2. Remove the horn switch screws and remove the switches. Installation 1. To install, reve ...

    Lamp Assembly - Fog Lamp (GT)
    Removal 1. Raise and support the vehicle. 2. Remove the screw. 3. Partially lower the vehicle and remove the fog lamp assembly. 1. Disconnect the electrical connector. 2. Remove the two screws. 3. Remove the fog lamp assembly and replace the bul ...