Front

Front Disc Brake Caliper/Description:

REMOVAL
1. Check fluid level in brake master cylinder reservoir. Remove brake fluid until brake master cylinder reservoir is half-full. Discard removed fluid.
2. Raise and support vehicle.
3. Remove wheel and tire. Use care to avoid damage to wheel cylinder bleeder screw or rotor shield.

NOTE: It is not necessary to disconnect hydraulic connections.

4. Remove two caliper guide pin bolts.
5. Lift disc brake caliper away from front disc brake rotor using a rotating motion.
6. Support the disc brake caliper assembly in a manner that will not stretch or damage the front brake hose, such as hanging from an s-hook or mechanics wire.
7. Remove brake shoe and lining assemblies from disc brake caliper anchor plate by sliding brake shoe and lining to off of front disc brake caliper anchor plate.
8. Inspect both disc brake rotor braking surfaces. Minor scoring or buildup of brake shoe and lining material does not require machining or replacement of the front disc brake rotor.
9. Hand-sand glaze off both front disc brake rotor braking surfaces using garnet paper 100A (medium grit) or aluminum oxide 150-J (medium grit).

Retracting Caliper:

INSTALLATION
1. Use a 10 cm (4 inch) C-clamp and wood block 70 mm x 25 mm (2 3/4 inch x 1 inch) and approximately 19 mm (3/4 inch) thick to seat caliper piston in its bore. This must be done to provide clearance for disc brake caliper assembly to fit over front disc brake rotor and pads during installation.
2. Install disc brake pads to front disc brake caliper anchor plate.





3. Make sure disc brake pad anti-rattle spring and disc brake pad anti-rattle clip is seated in caliper inspection opening. Disc brake pad anti-rattle clip must be installed from the lining side.
4. Inspect disc brake caliper locating pin and locating pin boots. If disc brake caliper locating pin is binding, remove and clean. Lubricate with Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M 1C171-A. If boots are torn, replace.
5. Install front disc brake caliper onto rotor and pads.
6. Install caliper guide pin bolts. Tighten lower bolt first to 28-36 Nm (21-26 ft. lbs.). Tighten upper bolt to 28-36 Nm (21-26 ft. lbs.).
7. Inspect disc brake caliper/front disc brake caliper anchor plate assembly to make sure brake shoes and linings are properly installed.

CAUTION: Failure to tighten lug nuts in a star pattern may result in high rotor runout which will speed up the development of brake roughness, shudder and vibration.

8. Install wheel and tire assembly, using Rotunda Accutorq Lug Nut Sockets 164-R0303 or equivalent on 1/2 inch drive air impact wrench or torque wrench to tighten lug nuts to 115-142 Nm (85-104 ft. lbs.).
9. Lower vehicle.
10. Pump brake pedal several times to position brake shoes and linings. Refill brake master cylinder with high performance Dot-3 Motor Vehicle Brake Fluid as necessary.
11. Road test vehicle.