This Ford Transit Connect came in with heavily corroded and lipped discs along with very low brake pads. The inner edge of the disc had a significant lip which would cause uneven wear with new pads, so a full disc and pad replacement was the right call on a van that does high mileage.
The brake setup on this Connect is the same as many other Ford models, so the procedure is transferable. The key extra step is cleaning the caliper carrier properly on the bench before fitting the new pads — this is what prevents binding, uneven wear and repeat jobs.
Tools & Parts Needed
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Step-by-Step Guide
Remove Wheel & Sliding Pin Covers
Remove the wheel (5x 19mm bolts). Turn the steering towards you to improve access. Pop off the two plastic dust covers — one top, one bottom — that cover the sliding pins on the caliper. These just prise off with a flat tool.
Remove the Sliding Pins & Caliper
Use a 7mm Allen key to undo both sliding pins — wiggle them out and set aside. If tight, a small screwdriver can help lever them free. With both pins out, remove the small spring clip at the front of the caliper by prying it off with a flathead screwdriver. The caliper is now free. Open the brake fluid reservoir cap so the piston has somewhere to go, then press the piston all the way back using a screwdriver against the old pad. Hang the caliper up to avoid stressing the brake line — do not let it hang free.
Remove the Pads & Caliper Carrier
Slide out both pads — note that the inner pad clips onto the piston. With pads out, undo the two 18mm bolts at the rear of the caliper carrier. These are tight — crack them off with a breaker bar. Once undone, lift the carrier off and take it to the bench.
Remove the Old Disc & Clean the Hub
The disc usually comes off by hand once the carrier is clear. If stuck, give it a firm tap with a hammer and it will come free. Use a wire brush to clean the face of the hub and the mating surface where the disc sits, removing all rust and debris so the new disc sits completely flat.
Clean the Caliper Carrier on the Bench
Clamp the carrier in a vice. Use a wire brush on all surfaces where the brake pads contact. Follow up with a flat file across the same surfaces to remove any rust ridges and lumps. The goal is completely flat, smooth contact areas. Turn it over and repeat on the other side. Also clean the mounting face where it bolts to the hub. This step takes time but is the most important part of the job.
Fit New Disc & Refit Carrier
Fit the shiny new disc onto the hub. Apply a thin smear of copper slip to the inner edge bore only — not the braking surface — to prevent future rust seizure. Refit the caliper carrier and tighten the 18mm bolts to spec. They should be done up nice and tight.
Fit New Pads & Reassemble Caliper
Apply a small amount of copper slip to the back edges of the new pads — not the friction material. The outer pad drops into the carrier. The inner pad clips onto the piston — it only goes on one way. Locate the caliper over the pads. Clean the sliding pins and lubricate with proper silicone brake grease before reinserting. Tighten both pins with the 7mm Allen key. Fit the plastic dust caps. Fit the new spring clip — bottom hole first, then rest the top in and push out and in to secure it. Tap with a hammer to ensure it is fully seated.
Refit Wheel & Bed In
Refit the wheel and lower the car. Pump the brake pedal several times before moving off to push the piston back out against the new pads. Top up brake fluid as needed. Bed in the new pads gently over the first few stops before applying full braking force.
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