How to Replace a Caliper in a Mercury Villager

The Mercury Villager minivan in no longer in production, so finding replacement parts like brake calipers can be tough. Consult an expert or mechanic on the right parts to use. It may be best to let these people handle all service on your Mercury vehicle.

Instructions

Raise the van securely on a jack stand and remove the wheel.

Disconnect the brake hose from the caliper at the fitting bolt. Discard the old washers on the bolt. Plug the hose with a small piece of plastic.

Unscrew and remove the two caliper pin bolts. Remove the caliper from the rotor; it should pivot upward and slide off. Be sure to not drip brake fluid onto the paint.

Make sure all parts are clean dirt and debris. If the replacement caliper's piston isn't bottomed in the bore, compress it in there with a C-clamp and a used brake pad.

Install the replacement caliper onto the rotor. See that the inboard and outboard brake pads are properly positioned.

Lubricate the locating pins with silicone grease or other dielectric compound. Install the two pin bolts into the caliper.

Connect the brake hose back to the caliper, using new copper washers with the banjo bolt.

Bleed the brake system to remove air. With a plastic hose connected to the bleeder valve, have another person depress the brake pedal several times, and then hold down on it.

Put the tire and wheel assembly back in place. Add extra brake fluid if needed. Lower the van.

Pump the brake pedal multiple times slowly until you have a firm pedal, indicating the brake pads are properly seated. Then road test the vehicle.