Difference between revisions of "Brake Caliper Rebuild Guide (Mondeo Mk2 - Part 1 of 3)"

Revision as of 03:36, 15 June 2011

Overview Guide
Ford Model:	Mondeo Mk3
Petrol/Diesel:	????
Estimated Cost:	?
Difficulty?	?????
Source	TalkFord.com http://www.talkford.com/topic/147497-mk3-brake-caliper-rebuild-guide
v • d • e

WORK IN PROGRESS http://www.talkford.com/topic/147497-mk3-brake-caliper-rebuild-guide/#LAST

This guide will walk you though completely striping down the callipers, cleaning, painting and rebuilding.

Step 1. Get your mk3 brake callipers, they should look like this:

Step 2. Undo the two calliper slider bolts:

Step 3. This will enable the brake pad carrier to split from the brake calliper like so:

Step 4. Now if you look at the brake pad carrier you have two threaded bars that are held in place by a rubber boot:

Step 5. Once pulled out they should look like below, note they are not the same, one has a rubber seal and the other is normal:

Step 6. Note the one with the rubber seal is the opposite side from the bleed nipple:

Step 7. Remove the two rubber boots, just pull them off, and with a flat blade screwdriver pick the rubber seal off the bar like so:

Step 8. Now that's the carrier done, now to the brake calliper its self

Step 9. Now we need to remove the piston from the brake calliper, you can try to remove it buy hand but this is very very hard! The best way is to use air to force the piston out, the first job is to place a thick rag to block the front of the calliper, and the reason for this is when you use air to remove the piston it will come out with some force!

Step 10. Place an air in the hole where your brake pipe will screw in to like so:

Step 11. Pop the piston out with your air gun, watch your fingers! :

File:Mondeomk3caliper11.jpg

Step 12. Pull the piston out:

File:Mondeomk3caliper12.jpg

Step 13. Now you should be left with this:

File:Mondeomk3caliper13.jpg

Step 14. Now you need to remove your dust boot, your best way is to get a head of a flat bladed screwdriver behind the boot, then twist to start to prise it out of its slot:

File:Mondeomk3caliper14.jpg

Step 15. Once it’s out you should look like this:

File:Mondeomk3caliper15.jpg

Step 16. Now you need to remove your piston seal, again just use a flat bladed screwdriver to remove the seal:

File:Mondeomk3caliper16.jpg

Step 17. Now you should have a striped down calliper looking like this ready to work on:

File:Mondeomk3caliper17.jpg

Step 18. Now comes the cleaning part, the time you spend cleaning will show when you come to paint them, if your happy with a ok finish then give them a degrease and paint, I wanted to see how good I could get this set, so first I steam cleaned them, soaked them in carb cleaner, this got all dirt and grease off them but they still looked ruff with flaked rust on the calliper, so next I got a like pin hammer and went right round the calliper knocking off all signs of rust, once done I wire brushed down, steam cleaned them at 3000 psi then de greased, again if you want a real good finish take your time and they will look fantastic, they took me 2 days to get them like this:

File:Mondeomk3caliper18.jpg

File:Mondeomk3caliper19.jpg

File:Mondeomk3caliper20.jpg

Step 21. Now it’s time to paint, I used bolts and two vices to hold the callipers and carriers while I painted, I just used silver hammerite (smoothrite), then I left them for 3 days gave them a second coat and left for a week to go nice and hard:

File:Mondeomk3caliper21.jpg

http://i33.photobuck...0CALIPER/22.jpg

http://i33.photobuck...0CALIPER/23.jpg

Step 24. Now I bought a new seal kit from ‘ Bigg Red Calipers ‘ part number ‘ 205729’ : http://i33.photobuck...0CALIPER/24.jpg

Step 25. I all so bought some red Castrol brake calliper grease (don’t use normal grease); you can get this from eBay: http://i33.photobuck...0CALIPER/25.jpg

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: http://i33.photobuck...0CALIPER/26.jpg

Step 27. Take your new piston seal, and lightly grease it: http://i33.photobuck...0CALIPER/27.jpg

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: http://i33.photobuck...0CALIPER/28.jpg

Step 29. Now get your piston and your new piston dust boot: http://i33.photobuck...0CALIPER/29.jpg

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: http://i33.photobuck...0CALIPER/30.jpg

Step 31. Pull the boot down until the top of the boot clips/slots on to the grove of the piston: http://i33.photobuck...0CALIPER/31.jpg

Step 32. Now lift the boot and it will sit in its home position: http://i33.photobuck...0CALIPER/32.jpg

Step 33. Lightly grease the piston: http://i33.photobuck...0CALIPER/33.jpg

Step 34. Place the piston in the calliper: http://i33.photobuck...0CALIPER/34.jpg

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: http://i33.photobuck...0CALIPER/35.jpg

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: http://i33.photobuck...0CALIPER/36.jpg

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! : http://i33.photobuck...0CALIPER/37.jpg

Step 38. Once happy push the piston all the way down in the home potion: http://i33.photobuck...0CALIPER/38.jpg

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: http://i33.photobuck...0CALIPER/39.jpg

Step 40. Bolt it in place and place you bleed nipple cover on: http://i33.photobuck...0CALIPER/40.jpg

Step 41. Get your calliper carrier rods and your new seal: http://i33.photobuck...0CALIPER/41.jpg

Step 42. Place your new seal on the rod, this will just slide on: http://i33.photobuck...0CALIPER/42.jpg

Step 43. Now grab your new calliper carrier dust boots: http://i33.photobuck...0CALIPER/43.jpg

Step 44. Pop your rod dust boots in the carrier, these just pop in: http://i33.photobuck...0CALIPER/44.jpg

Step 45. Lightly grease the two rods in the calliper grease: http://i33.photobuck...0CALIPER/45.jpg

Step 46. Push the rods in the carrier until the rods clip in to the boots: http://i33.photobuck...0CALIPER/46.jpg

Step 47. Now bolt the carrier to the calliper: http://i33.photobuck...0CALIPER/47.jpg

Step 48. Job done: http://i33.photobuck...0CALIPER/48.jpg

http://i33.photobuck...0CALIPER/49.jpg

http://i33.photobuck...0CALIPER/50.jpg

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