Published On Jan 18, 2018
Changing the rear brake caliper and working with the brake line, on a Ford Mondeo 2002... or, the basics of replacing a floating caliper with inbuilt parking brake, including aligning the piston correctly. See notes below.
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You will need:
* Replacement caliper to suit
* Jack, axle stands, wheel nut socket & wrench
* Flare nut spanners: 14 mm (caliper brake line fitting), 11 (or possibly 10) mm (bleed valve & upper brake line fitting). Amazon US: http://amzn.to/2rkSzum | UK: http://amzn.to/2mNEKPo
* For upper brake line fitting (maybe): 17 mm open spanner
* For retaining bolts: 13 mm hex socket and breaker bar...
* ... and torque wrench (tighten to 30 NM), shown used is Tekton 24335 1/2". Amazon US: http://amzn.to/2g1zGoJ | UK: http://amzn.to/2gJ7sAg
* Medium strength threadlocker. Amazon US: http://amzn.to/2DN3Upv | UK: http://amzn.to/2mTuVAv
* Long nose pliers, or...
* ... 12 mm hex key or bit, or...
* ... Other winding adapter tool to suit. Amazon US: https://amzn.to/38FNNcc | UK: https://amzn.to/2PJULo3
* Vice grips
* Brake fluid, Super Dot 4. Amazon US: http://amzn.to/2BbX6Pb | UK: http://amzn.to/2DRlatX
* Self-bleed kit (if no assistant). Amazon US: http://amzn.to/2rk35Sm | UK: http://amzn.to/2EUAULK
* Anti-seize copper or nickel based. Amazon US: http://amzn.to/2rlBU9Z | UK: http://amzn.to/2Beksni
* Brake clean. Amazon US: http://amzn.to/2DNbGj6 | UK: http://amzn.to/2Bfp4d4
* Rags.
== Tentative notes on retracting and aligning the piston for the Mondeo Mk3: ==
To 09-2004:
Left side ~ Align circular cutout on piston with raised nib. (This is the one shown in the video).
Right side ~ Align circular cutout on piston opposite raised nib.
Retract the brake caliper piston using an Allen key and applying pressure.
4 & 5 door ~
Retract left side by rotating COUNTERCLOCKWISE.
Retract right side by rotating CLOCKWISE.
Estate/wagon ~
Retract left side by rotating CLOCKWISE.
Retract right side by rotating COUNTERCLOCKWISE.
From 09-2004:
Align indents in the brake caliper pistons with the brake pad locating pins.
Retract the brake caliper piston using winding tool.
4 & 5 door ~
Retract left side by rotating CLOCKWISE.
Retract right side by rotating COUNTERCLOCKWISE.
Estate/wagon ~
Retract left side by rotating COUNTERCLOCKWISE.
Retract right side by rotating CLOCKWISE.
CHECK that the piston is moving as expected as orientations have been known to vary.
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