2005-2007 Hybrid brake caliper

Brake Caliper, Front - Hybrid

Material
Removal and Installation

WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury.

WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in personal injury.

CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.

CAUTION: Do not allow brake fluid to overflow from the master cylinder reservoir. Brake fluid may damage the high-voltage components.

NOTE: The rear brake pads will wear at approximately twice the rate of the front brake pads.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.
   
   [/*]
2. NOTE: These steps must be followed to prevent the accumulator from charging and pressurizing the brake system.
   
   Disconnect the battery. For additional information, refer to Battery.
   
   [/*]
3. Remove the battery junction box (BJB) fuses 24 (50A) and 31 (50A).
   
   [/*]
4. Remove the brake caliper clip.
   
   [/*]
5. Loosen the brake caliper jounce hose at the brake caliper.
   • To install, tighten to 20 Nm (15 ft. lbs.)[/*]
   [/*]
6. Remove the 2 brake caliper dust boot caps.
   
   [/*]
7. Remove the 2 brake caliper guide bolts.
   • To install, tighten to 45 Nm (33 ft. lbs.)[/*]
   [/*]
8. Remove the brake caliper.
   • Unthread the brake caliper from the brake caliper jounce hose.[/*]
   [/*]
9. NOTE: Make sure that the brake caliper jounce hose is not twisted.
   
   To install, reverse the removal procedure.
   • Bleed the brake system.[/*]
   [/*]

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Brake Caliper, Rear - Hybrid

Material
Removal and Installation

WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury.

WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in personal injury.

CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.

CAUTION: Do not allow brake fluid to overflow from the master cylinder reservoir. Brake fluid may damage the high-voltage components.

NOTE: The rear brake pads will wear at approximately twice the rate of the front brake pads.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.
   
   [/*]
2. NOTE: These steps must be followed to prevent the accumulator from charging and pressurizing the brake system.
   
   Disconnect the battery. For additional information, refer to Battery.
   • Remove the battery junction box (BJB) fuses 24 (50A) and 31 (50A).[/*]
   [/*]
3. NOTE: Install new copper washers.
   
   Remove the brake caliper jounce hose flow bolt and discard the 2 copper washers.
   • To install, tighten to 35 Nm (26 ft. lbs.)[/*]
   [/*]
4. Remove the 2 brake caliper guide bolts.
   • To install, tighten to 35 Nm (26 ft. lbs.)[/*]
   [/*]
5. Remove the brake caliper.
   
   [/*]
6. To install, reverse the removal procedure.
   • Bleed the brake system.[/*]
   [/*]

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Brake Caliper Anchor Plate - Hybrid

Removal and Installation

• NOTE: These steps must be followed to prevent the accumulator from charging and pressurizing the brake system.
  Disconnect the battery. For additional information, refer to Battery.
  
  [/*]
• Remove the battery junction box (BJB) fuses 24 (50A) and 31 (50A).
  
  [/*]
• Remove the brake pads.
  
  [/*]
• Remove the 2 brake caliper anchor plate bolts.
  • To install, tighten to 175 Nm (129 ft. lbs.)[/*]
  [/*]
• Remove the brake caliper anchor plate.
  
  [/*]
• To install, reverse the removal procedure.[/*]

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