Expanded Slide pin rubbers.

Ford Mondeo 2nd Generation 2001 Estate

I was refurbishing some rear calipers mildly while waiting for a repait kit. The left side got unstuck fine but the right side is still recalcitrant. Could a swollen slide pin rubber cause the caliper to seize in a manner that prevents the hand brake mechanism (Disc brakes no drum) from operating correctly? The mechanism was free when it was broken up and jammed again when i fully reassembled the caliper. The cable is free so that's not the problem.

Did you clean out slide pin holes with a bore brush to remove rust build up and old lubricant and relubricate pins with petroleum technical?

Also what color is the brake fluid clear or dark? You might have corrosion on the caliper pistons if its dark and should be fully disassembled cleaned and honed.

The self-adjuster mechanism on these frequently gets knackered by incorrect adjustment also if it has the type of guide pin in the picture they are very prone to being damaged ie bent during pad replacement. To pull a badly damaged bent pin out use the pin's thread and a bolt to Mcgyver an extractor.

The handbrake cable must not be over tensioned and condition of the hairpin spring are vital for correct operation of the self-adjuster mechanism

The brake fluid is practically new and theres nothing wrong with the stopping power. But right rear and left front don't properly disengage. I am going to get at bore brush when I get the repair kit in the mail. Both pistons move no problem wehen you retract them. The right rear was really hard to get back in so i suspect it "hydro locks" whenit gets near the bottom.

It has automatic ajustment at the lever end and is not over tensioned. The pins are not bent. Ill change the supect one anyway because the threads are bad in it.

It's this type. cdn.autodoc.de/uploads/360_photos/14644612/preview.jpg

What kind of grease did you use on the pins? If it was anything other than silicone it might have caused those rubber sleeves on the pins to swell up.

It's a none metalic brake caliper/parts grease but I don't know what has been used previously. Something white. Very similar to this is what i used. www.mekster.se/bosch-bosch-superfit-649614.html .