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Installing brake caliper sleves

Article by GhostDog


Everyone who has ever jumped into a Fox body mustang knows both the unrivaled power the 5.0L engine and of the unending aftermarket that supports it. One product the aftermarket has designed is very small but very effective. Maximum Motorsports has developed replacement stainless steel brake caliper bushing sleeves to replace the factory rubber bushings. They describe their purpose best as "The rubber bushings let the calipers move during braking, preventing the pad from contacting the rotor surface squarely. This movement reduces your brakes' effectiveness and leads to tapered pad wear."


Although MM online instructions call for removing of the brake caliper and bleeding of the brake system, this is not required. For those of you who also have upgraded your stock 60mm piston calipers to Mark VII 73mm piston calipers, these will also fit your calipers. This guide is shown installing on Mark VII calipers.
When you compare the heavy duty construction of these sleeves you will notice immediately that the factory bushings could definitely cause uneven braking due to the flexible nature of rubber.

The first step to installing these brake caliper sleeves is safety. Chock both rear tires and pull the hand brake inside. Loosen all lug nuts and raise the car onto jack stands. Remove the tires and keep the lug nuts in a plastic bag or on top of the car to avoid misplacing them.


In the next picture the brake caliper and rotor are exposed. There are two 5/8" bolts that hold the caliper onto the rotor. You must loosen the bolts so they clear the threaded part of the caliper and then pull the bolts out of the rubber bushing by hand.
Remove both now to allow the caliper to move into a position where the old bushings can be removed and the new bushings can be installed. Once both bolts are removed, pull the top portion of the caliper towards the rear of the car as shown. This will allow room to remove the old rubber bushing. To remove the old bushing, I used two regular flat screwdrivers. Push one side of the bushing towards the center.


Hold that side of the rubber bushing while pushing the opposite side with the other screw driver.
Once the fat part of the bushing is inside the hole, gently pull back of the bushing with pliers or with your hands. Now you will have an empty caliper bolt bushing bore.



With the new bushing, align it inside the bore so it will enter fairly straight. It will straighten out if it is not completely center.
With your C-Clamp, position it so that the back side of the clamp contacts the caliper. Begin tightening the clamp. The sleeve should slide in with ease and have a nice, tight fit. The brake caliper sleeve with not go in as far as necessary with the C-Clamp. This is due to the clamp blocking the sleeve from going further. This picture shows as far as it will go with the C-clamp.


To finish the job, you will need to only gently tap the sleeve in further with a hammer.
The end result is as shown. The sleeve is completely flush against the caliper and will not go in further.
Now we must tackle the bottom caliper bolt sleeve. Begin to rotate the caliper so that the bottom portion is in a position to remove the old bushing. The brake pad may move in the way while positioning the caliper, simply position it where it will not interfere.

Manipulate the old rubber bushing out of the bore with the screwdrivers and pull out by hand or with pliers.
Insert the new bushing and push it in as straight and hard as you can by hand.
Position the C-clamp with the part where you tighten towards the center of the car. It may help to turn the wheel to gain clearance.


Once again we are faced with the bushing not being able to go in completely because the C-clamp blocks it from going further.
Use the hammer once again to tap in the remaining part of the bushing into the bore.
Once the sleeve is installed all the way you are done.

Reinstall the caliper onto the rotor and reposition the bolt holes so they line up. It should look like this.
With the bolts in place your brakes should look like this.

Written Dec. 2004 by Freddy Lozano for All Ford Mustangs


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