In order to get rid of FS/11 calipers, one must first apply the handbrake, jack up the front of the car and place it on axle stands before taking off the front roadwheels. Disconnect the wear sensor wiring of the brake pad, and observe the routing and release it of any attaching clips. Where necessary, open the air deflector shield to access it better. Take the two protective rubber caps off and slacken the caliper guide pins using a hexagon key and then lift the caliper with pads off the hub carrier and then attach it to the suspension strut being careful not to leave the caliper hanging freely on the flexible brake hose. Remember to remove the two brake pads, the inner pad being secured by a spring clip and label the original pads so that they can be replaced later. Check the thickness of each brake pad; in case some are worn to the lowest limit, or are covered with oil or grease, all four pads are to be changed. Clean serviceable pads using a fine wire brush, making sure to clean the grooves and pad locations of the caliper. Ensure that the guide pins move smoothly and look at the dust seal and the piston in terms of damage or leakages. When new pads are being installed, push the caliper piston back against the cylinder with a G-clamp or other such tool, and be careful to control the flow of the brake fluid to prevent any breakage of the master cylinder seals. Install the new pads with the inboard pad labeled as piston side and place the caliper on the
Brake Disc and fit the lug on the hub carrier. Install the caliper guide pins using copper grease and apply the pin to a desired torque without the force being excessive, and may cause the pad spring to deform. Reconnect brake pad wear sensor wiring (where present), and press the brake pedal several times until the normal pedal pressure is regained. Do the same with the other front brake caliper, and re-fit the roadwheels, lower the vehicle, and screw up the roadwheel bolts. The new pads will take time to break-in, and therefore, do not hard-brake in the first hundred miles. In the case of FN3 calipers, one must first start by removing the spring holding the brake pad, the caliper guide pins and then lift the caliper, making sure it is secured in the same manner. Take off the brake pads and observe the position of the pads. In refitting, the outer pad has to be in place against the brake disc then the inner pad with the retaining clip. Fix the guide pins and re-install the retaining spring, and reconnect the wear sensor wiring, when needed. Lastly, release brake pedal until normal pressure has been regained, repeat on the other caliper, replace roadwheels, lower the vehicle and observe the level of hydraulic fluid bearing in mind the bedding-in time of new pads.