How to: Replace rear brake caliper (Ford Mondeo Mk3)
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- เผยแพร่เมื่อ 18 ก.ย. 2024
- 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: amzn.to/2rkSzum | UK: 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: amzn.to/2g1zGoJ | UK: amzn.to/2gJ7sAg
* Medium strength threadlocker. Amazon US: amzn.to/2DN3Upv | UK: amzn.to/2mTuVAv
* Long nose pliers, or...
* ... 12 mm hex key or bit, or...
* ... Other winding adapter tool to suit. Amazon US: amzn.to/38FNNcc | UK: amzn.to/2PJULo3
* Vice grips
* Brake fluid, Super Dot 4. Amazon US: amzn.to/2BbX6Pb | UK: amzn.to/2DRlatX
* Self-bleed kit (if no assistant). Amazon US: amzn.to/2rk35Sm | UK: amzn.to/2EUAULK
* Anti-seize copper or nickel based. Amazon US: amzn.to/2rlBU9Z | UK: amzn.to/2Beksni
* Brake clean. Amazon US: amzn.to/2DNbGj6 | UK: 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.
=====
Using the above Amazon links helps support my channel and is appreciated!
Amazon links to relevant products (from the description):
* Flare nut spanners/wrenches - Amazon US: amzn.to/2rkSzum | UK: amzn.to/2mNEKPo
* Caliper winding tool - Amazon US: amzn.to/38FNNcc | UK: amzn.to/2PJULo3
* Tekton 1/2" torque wrench - Amazon US: amzn.to/2g1zGoJ | UK: amzn.to/2gJ7sAg
* Threadlocker - Amazon US: amzn.to/2DN3Upv | UK: amzn.to/2mTuVAv
* Anti-seize - Amazon US: amzn.to/2rlBU9Z | UK: amzn.to/2Beksni
* Brake fluid - Amazon US: amzn.to/2BbX6Pb | UK: amzn.to/2DRlatX
* Brake bleed kit - Amazon US: amzn.to/2rk35Sm | UK: amzn.to/2EUAULK
* Brake clean - Amazon US: amzn.to/2DNbGj6 | UK: amzn.to/2Bfp4d4
Great video! Thanks for sharing. What's the best way to get in-touch with you please? Thank you.
I think this is the favourite of all the car DIY videos I've ever watched and I'm easily in the thousands. Good job man.
Looks like a common issue on early MK3. Rear left brake caliper is seized on my MK3 hatch, going to replace the caliper, slider pins and handbrake cables. Thank you for the video!
Handbrake lever in the caliper is what seizes. PITA
Hi , I really want to say thankyou so much for your video , we've not got a lot so advice like this is priceless . I'm no mechanic but his video really helped me . Within 2 hours job done ( don't judge on time taken) . Thankyou again.
Nice informative video. Done this before and have another one to do today so needed a quick refresher. Easy to follow, thanks!
Very good video, all the important points covered and clearly narrated
Great video! Very informative and your calm soothing voice is the icing on the cake! Thanx!
one of the best how 2 vids, I dont have this kind of car (just checkin for someone else), grrrrreat ...
Thanks for this vid need to sort mine this week and this vid makes it a lot easier now I know where to start 👍🏼👍🏼
Great job! Purely as a surgeon!
Excellent video, very well explained.
Brilliant tutorial as usual thanks !
Brilliant, well done
Good videos and surprisingly cultured voice, considering you are showing us 'grease monkey' work!
Hi Craig yet another amazing informative video of yours that's added to my favourite list... I have a 2005 Mondeo and i was wondering since you mentioned it what is the difference between the caliper you have there and the newer type?
Peace
Practical differences w.r.t. piston winding directions are in the desc. You can look up pictures to see visual differences. Otherwise I don't know what the technical changes were. The pre-facelift (featured) types have a habit of seizing up and that seems to have been improved.
Craig's DIY Car ... lol yeah i have a few seized ones from my 2001 MK3 Mondeo lurking in a cupboard that i planned to fix up but never seem to get round to it. Thanks for the info buddy.
Peace
My rear right brake calipers handbrake engages later than the left one, what could be the problem? the movement of the wire is the same on both sides of the car, I have measured it on different "notches" of the brake lever inside the car. Can you explain more in detail how to position the piston, there are two slots in the piston, could I choose both of them and it still would work? if you have a good video on how to position these and what else could be wrong if it engages at different notches but still are strong on both sides. it engages pretty strong on the first notch on the left side, I can't rotate the brake disc by hand but on the right side its engaging in the same way on the third or fourth notch.
I have a 55 plate 2.0 TDCi and both callipers rotate back in the same way not clockwise and anti-clockwise
Hang on, you checked that you had the right caliper AFTER you sprayed the new one black?😀
Retracting the LEFT piston done on this video is CW but description says CCW for old type 4 door version, so what is correct???
I'm not retracting it in the video, I'm just aligning it by moving it the least amount. The caliper was a recond unit with piston already retracted and my pads are half worn anyway.
What year is this car of yours? On my 2004 facelift it didn't have the clip for locking the handbrake wire - so i wonder if they made a change on the facelift
Pre-facelift
You have made some good videos. Why the pistons have to be aligned? In my case my Mondeo's right break caliper (piston surface) was the same as in the video but the left rear brake caliper (or the piston) was different and it had only two round holes. Now I don't know which hole has to be aligned with the raised nib.
It's to do with the internal mechanism. On the later version which I take it you have, I believe the alignment can be either way, i.e. just either of the holes adjacent the nib. See the notes in the description.
My Mondeo is 2001. I also noticed a difference in the parking brake lever. This is my setup 1drv.ms/u/s!Aq6X7BC-M97tkhY2bG_bFBzN5peM
Sorry I'm not sure. Is your car an estate, they are different but the principle is the same. If you align either of the holes it should be fine. As to the handbrake have you seen my handbrake video, re the difference self-adjusting vs manual. It shows both.
Or you meant on the caliper again, yes the lever design there differs but the principle is the same on all.
Ok...my car is estate. Yes, I meant the handbrake/parking brake lever at the caliper which according to many videos can be either up or down. It seems that my calipers springs force is not strong enough to return the lever when handbrake cables are attached. Cables are not so stiff and I have also lubricated them.
Hi Craig, I noticed in your dashcam install video you are passing through the Auckland Harbour bridge. so are you in NZ? If so, my next question is where did you get the refurbished caliper? Cheers
From the UK. Not possible to buy at reasonable price locally.
So retracting in my model 2002 wagoon, driver side, means turning it by Allen key which way? Thanks in advance
If by driver side you mean RH, then it should be CCW on a pre-2004 wagon. Use common sense and watch what it does as you try.
@@CraigsDIY thanks, do you know the allen key size to rotate the piston? I am afraid my biggest is 10mm.
Apparently it's 12 mm. (I didn't check mine). If you're buying a new tool, a hex bit for a ratchet handle might be ideal.
hi there looking for advice,recently changed calipers on my 2005 mondeo now my handbrake is not holding even after adjusting. is this down to caliper piston positioning.
After install the piston will sort itself out once you pump the brake pedal a few times, as covered in the video. So if the foot pedal is giving you brakes, the handbrake problem must be in either the caliper lever, the cables, or the handbrake itself. Watch what is happening at the caliper lever(s) when you pull the handbrake on and off. And refer to my other videos on the handbrake & cables for more detail.
I’m having the same problem ... no hold and after changing both handbrake cables and both callipers I’m getting a n/s rubbing sound from the disk and pad
Hi Craig. Where did you buy your caliper and rear hose assembly from please?
Off eBay, this one is a re-cond unit, recently I bought a new one for the other side that is a Polish manufacturer, seems good so far. Part of my calculus is shipping cost to the Antipodes so YMMV.
How the hell did you manage to put back the handbrake cable that easy, did you adjust the slack of the wire or something? For me it's totally impossible and i cannot even clamp on the same kind of pliers that i see you use. Please explain better
At the caliper? Grab cable end with pliers and use vice grips to turn the caliper handbrake lever toward it. That should always give you enough room. If not a) I would say maybe cable is adjusted too tight but b) how did you get it off the old one.
Complete notes on aligning and retracting the caliper pistons, covering all Mondeo Mk3 models 2000-2007, are in the description.
piss poor video not the way to change out a rear calliper uk ford tech 40 years at fords
It's the same way I did mine a few months ago (mechanic for a living) and absolutely no problems whatsoever. It's one of the clearest videos on here for what's a daunting job for a lot of people.
May i ask why you have that opinion?
Paul where’s your video to show the correct way ?