Caliper

Disassembly

1. Remove rear disc brake caliper (2552) assembly from vehicle as outlined.

2. Mount rear disc brake caliper in a vise. Use vise jaw protectors.

3. Using Rear Caliper Piston Adjuster T87P-2588-A, turn rear disc brake piston and adjuster (2B588) counterclockwise and remove rear disc brake piston and adjuster from caliper piston bore.

4. Remove and discard piston dust boot seal and piston seal from caliper bore.

    CAUTION: The snap ring (circlip) and spring cover are under spring load and care should be taken when removing the snap ring (circlip).

5. With suitable snap ring (circlip) pliers, remove snap ring (circlip) retaining push rod assembly from rear disc brake caliper .
   
   
   
   
   

   Item	Part Number	Description
   1	—	Parking Brake Spring Retainer (Part of 2552)
   2	—	Flat Washer (Part of 2552)
   3	—	Adjuster Nut (Part of 2B588)
   4	2552 RH 2553 LH	Rear Disc Brake Caliper
   5	2B588	Rear Disc Brake Piston and Adjuster
   6	—	Piston Dust Boot (Part of 2L128)
   7	—	Piston Seal (Part of 2L128)
   8	—	Locating Washer (Part of 2552)
   9	2A746	Parking Brake Lever Pin Retainer Clip
   10	2B164	Brake Shoe Hold Down Spring
   11	—	Parking Brake Lever Shaft Seal (Part of 2L128)
   12	—	Strut Pin (Part of 2A637)
   13	2A637	Rear Parking Brake Cable
   14	—	Push Rod (Part of 2552)

6. From caliper bore, remove spring cover, spring, washer, key plate and pull out push rod and strut pin.

7. Remove and discard o-ring seal (9229) from push rod.

8. Remove parking brake return spring (2456) , unscrew limiting bolt (2A795) and pull rear parking brake cable (2A637) out of rear disc brake caliper .

Assembly

1. Lightly grease parking brake lever bore and lever shaft seal with Silicone Dielectric Compound D7AZ-19A331-A (in Canada, Motorcraft WA-10) or equivalent meeting Ford specification ESE-M1C171-A. Press parking brake lever shaft seal into caliper bore.

2. Grease parking brake shaft recess and slightly grease rear parking brake cable . Insert rear parking brake cable into bore in caliper housing.

3. Screw limiting bolt into caliper housing. Tighten to 6-9 Nm (4.5-7 lb-ft). Attach parking brake return spring to limiting bolt and insert free end into rear parking brake cable slot.
   
   
   
   
   

   Item	Part Number	Description
   1	2L642	Parking Brake Return Spring
   2	2A637	Rear Parking Brake Cable
   3A	2A795	Limiting Bolt
   4	—	Parking Brake Lever Shaft Seal (Part of 2L128)
   5	2N1221 (RH)	Caliper Housing
   A		Tighten to 6-9 Nm (4.5-7 Lb-In)

4. Install new o-ring seal in groove of push rod. Grease recess at push rod end with Silicone Dielectric Compound D7AZ-19A331-A (in Canada, Motorcraft WA-10) or equivalent meeting Ford specification ESE-M1C171-A.

   NOTE: Tools used in Steps 6 through 9 are part of Caliper Spring Compressor Set T87P-2588-B.

5. Position strut pin into rear disc brake caliper and in recess of rear parking brake cable . Insert push rod into push rod bore of rear disc brake caliper . Ensure pin is positioned correctly between shaft recess and recess at end of push rod. Place key plate over push rod so that locating nib fits into drilled locating hole in rear disc brake caliper . Install flat washer push rod spring and spring cover in order.
   
   
   
   
   

   Item	Part Number	Description
   1	2552	Rear Disc Brake Caliper
   2	—	Strut Pin (Part of 2552)
   3	—	Push Rod (Part of 2552)
   4	—	Flat Washer (Part of 2552)
   5	—	Spring Retainer (Part of 2552)
   6	—	Spring (Part of 2552)
   7	—	Key Plate (Part of 2552)

6. Insert outer spacer into piston bore.
   
   
   
   

7. Insert inner spacer into piston bore.
   
   
   
   

8. Place snap ring inside of inner spacer.
   
   
   
   

    CAUTION: Snap ring should "click" into place. Do not over-compress spring.

9. Position spring compressor, and screw and cross-block on push rod and lightly screw tool clockwise to compress spring. Install snap ring (circlip).
   
   
   
   

10. Install new piston seal in groove in rear disc brake caliper after lubricating seal with Heavy-Duty Brake Fluid C6AZ-19542-AA or BA or DOT 3 or equivalent meeting Ford specification ESA-M6C25-A.

    NOTE: Ensure one slot in piston face is positioned so it will engage with nib on rear brake shoe and lining (2200) .

11. Coat rear disc brake piston and adjuster and piston dust boot with clean brake fluid C6AZ-19542-AA (ESA-M6C25-A) or equivalent. Install dust boot into piston bore of rear disc brake caliper . Spread dust boot over rear disc brake piston and adjuster and seat dust boot in piston groove. Rotate rear disc brake piston and adjuster clockwise using Rear Caliper Piston Adjuster T87P-2588-A or equivalent until piston is fully seated.

12. Install rear disc brake caliper assembly as outlined.