Brake Pad: Service and Repair

Removal

WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately.

1. If new pads are to be installed, provide space for the brake fluid displaced from the disc brake caliper.
- Remove and discard enough brake fluid from the brake master cylinder to allow room for the brake fluid displaced when the caliper piston is pressed to the bottom of the caliper bore.
2. Raise and support the vehicle.
3. Remove the tire and wheel assembly.





4. If so equipped, unclip the speed sensor wiring from the front brake hose.





5. Remove the two disc brake caliper bolts.

6. CAUTION: Do not allow the disc brake caliper to hang from the front brake hose. Use wire to support the disc brake caliper from a convenient underbody component.





Remove the disc brake caliper from the front wheel spindle (E-150) or from the front disc brake caliper anchor plate (E-250, E-350, E-450).





7. Inspect:
- the disc brake caliper for brake fluid leakage. If the disc brake caliper is leaking, it must be rebuilt or installed new.
- the pad thickness. Do not install pads worn to or past the specified thickness above the metal backing plate or rivets.
- the pads for contamination. Do not put oil or grease-contaminated pads on vehicle.
- the brake disc and hub for minimum thickness. Install a new brake disc and hub if worn to or below minimum thickness.

Installation

1. Note: Bottoming of the caliper piston is not necessary if reusing the original pads.

If installing new pads, use a C-clamp and a pad to press the caliper piston to the bottom of the caliper bore.





2. CAUTION: To prevent deterioration of the caliper sleeve boots, do not use petroleum-based lubricant.

Fill the rubber caliper sleeve boots with Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A.





3. Install the disc brake caliper.
1 Position the disc brake caliper in the front wheel spindle (E-150), or in the front disc brake caliper anchor plate (E-250, E-350, E-450).
2 Install and tighten the disc brake caliper bolts.





4. If so equipped, attach the speed sensor wiring to the front brake hose.
5. Install the tire and wheel assembly.