Help needed with Ford Fusion/Mazda 6 brake job

[w123driver]

I am stuck with rear brake job on my Ford Fusion. Can anyone please help me with this. These are disc brakes and identical on Mazda 6. I was trying to push back caliper piston to install new pads. Someone told me these pistons can not be pushed back by pressing, but rather need to be turned clockwise. Looks like I tore the rubber boot while turning this thing.






Do I need to replace the whole caliper, or the is it possible to replace the rubber boot?

The other problem I am having is that two torx screws that hold the rotor on place, had completely stripped heads.
This picture shows the rotor on rith side, with intact heads:



This is the other rotor.



I tried to drill awhole through it in an attempt to bite with large torx head, but the drill wont go further. I than cut slots with dremel to bite with flat screwdriver, but this did not work either… Is there anything else I can try to take this rotor out? Thank You!

[muddeprived]

Do you got an ez out? Sears has a nice ez out kit. Drill a hole the size of the torx bit hole that was on there (use lube on the drill bit and drill SLOW so the bit doesn't become dull). You have to drill a small hole first and step up in size. Stick the ez out in there and punch it in once or twice with a hammer. Use a MAPP torch on the bolt for a good 30-45 seconds before you attempt to twist it out and it should come out. Try the MAPP torch on the others before you attempt to remove em. They might have used locktite on the bolts from the factory.

It looks like you are real close to drilling off the entire head of the bolt to where you can pull the rotor off of it and then have some bolt sticking out to grab with a small pipe wrench.

For the caliper, it looks like the boot got folded in? I can't really tell. If so, extend the caliper again to get the boot seated right.

Are you using an impact gun?

[mcatald]

You need a special tool to twist the caliper piston as you push it in. You can pick up a basic fit all version of the tool at Carquest or Napa its made by Lisle.

Drill that screw out and forget about it.

As for the boot you can get them as part of a caliper rebuild kit. Is it actually torn or just rolled out a bit? That is a dust boot.

[w123driver]

Thanks guys. I tore the boot while twisting the piston, did not realize that the rubber was twisting around metal. Neither Ford dealer, nor NAPA don't sell repiar kit, they would sell entire caliper

Wonder if I can take this thing apart; perhaps a boot from another make/model caliper would fit. dealr wants $350 for one caliper... NAPA wants $70 for rebuilt one.
I am very happy with car otherwise, but the brake pads gone at 30K? I drive this car gently as a grandma.

[muddeprived]

Originally Posted by w123driver

Thanks guys. I tore the boot while twisting the piston, did not realize that the rubber was twisting around metal. Neither Ford dealer, nor NAPA don't sell repiar kit, they would sell entire caliper

Wonder if I can take this thing apart; perhaps a boot from another make/model caliper would fit. dealr wants $350 for one caliper... NAPA wants $70 for rebuilt one.
I am very happy with car otherwise, but the brake pads gone at 30K? I drive this car gently as a grandma.

Maybe the rears need adjusted to help the fronts? I don't know much about those new cars......i hate cars.

Or maybe it's just the crappy FORD parts.

[w123driver]

Well, the pads are tiny for a cars this size, and the rotor is only 10 mm thick.

The piston is precisely 34 mm in diameter. These 2 pieces are what used to be the dust boot



this is lip on inner side.



Someone must be selling this little piece of rubber separately...

[muddeprived]

Hey man, check out RockAuto Auto Parts

RAYBESTOS Part # H16089

If that's not it, check out the "caliper repair kit" under your ford fusion year.

I think they have the "caliper bushing" kit you need. It looks like what you are showing us there.

[mcatald]

30,000 miles out of a set of Ford pads is pretty good. On passenger cars Ford likes to use an organic pad to help reduce brake noise, the down side is they wear faster and can be kind of dusty.

I can't believe how bad stuff corrodes from the salt you guys use back east, so don't be to tough on yourself over that caliper.

I priced 4 different manufactures calipers when I was at work and was a bit surprised at the price. That reman from NAPA seems pretty reasonable.

Good luck with it and keep us posted on your progress.

[w123driver]

Whoa, that seems to be the same bushing. Thanks!