Brake Caliper Rebuild Guide (Mondeo Mk2 - Part 3 of 3)

The Ford Mondeo hit our roads in 1993, and has consistently been a sales success. Now on its 4th incarnation, it remains a drivers favourite.
For more information, visit the Ford Mondeo forum on TalkFord.com, the definitive resource site covering all Fords from the present day to the 1970's.

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Overview Guide
Ford Model:	Mondeo Mk3
Petrol/Diesel:	????
Estimated Cost:	?
Difficulty?	?????
Source	TalkFord.com

Due to the length and the amount of photos for this wiki guide, it has been broken down into the following sections:

Part 1 - Stripping Down The Calipers

Part 2 - Cleaning

Part 3 - Rebuilding

Step 24. Now I bought a new seal kit from Bigg Red Calipers part number 205729:

Step 25. I all so bought some red Castrol brake calliper grease (don't use normal grease); you can get this from eBay:

Step 26. Now you need to clean your piston up, I just used some soft wire wool, don't use any thing harsh as these have a chrome coating and you don't want it damaged the main bit you need to worry about is the piston below the dust boot ring:

Step 27. Take your new piston seal, and lightly grease it:

Step 28. Now with new clean rag clean the inside of the piston housing, lightly grease it and pop your new piston seal in, make sure there are no twists or kinks:

Step 29. Now get your piston and your new piston dust boot:

Step 30. With the piston facing up slide your dust boot on to the piston, note that the boot has to go on a certain way, face with the squares on face out, on the other side of the dust boot there are 3 dots, this side faces in, look at the pic to see what I mean:

Step 31. Pull the boot down until the top of the boot clips/slots on to the grove of the piston:

Step 32. Now lift the boot and it will sit in its home position:

Step 33. Lightly grease the piston:

Step 34. Place the piston in the calliper:

Step 35. Now place your fingers either side of the piston and press the piston in to the calliper making sure you press it in square, it will be tight but should slot it nice, press it all the way down until it's in the home position:

Step 36. Now you need to press the seal in, the dust boot has a metal outer ring, this fits tight in to the calliper, round the outside use a flat/round punch, and with a small hammer tap round the outside to knock the boot in place, and this can be tricky but will pop it fine:

Step 37. Pull the piston up to check your boot, you don’t have to do this but it is nice to double check, it can be very very tight to pull the piston up! :

Step 38. Once happy push the piston all the way down in the home potion:

Step 39. Next get your grease nipple, and you need to screw it back in to your calliper, I put the red grease on mine as when you come to bleed your brakes, the grease will help stop any air being drawn in though the threads:

Step 40. Bolt it in place and place you bleed nipple cover on:

Step 41. Get your calliper carrier rods and your new seal:

Step 42. Place your new seal on the rod, this will just slide on:

Step 43. Now grab your new calliper carrier dust boots:

Step 44. Pop your rod dust boots in the carrier, these just pop in:

Step 45. Lightly grease the two rods in the calliper grease:

Step 46. Push the rods in the carrier until the rods clip in to the boots:

Step 47. Now bolt the carrier to the calliper:

Step 48. Job done:

Now all you have to do is bolt them back to the car, bleed your brakes and all is good.

Due to the length and the amount of photos for this wiki guide, it has been broken down into the following sections:

Part 1 - Stripping Down The Calipers

Part 2 - Cleaning

Part 3 - Rebuilding