Removal
1. Remove brake master cylinder filler cap. Check fluid level in brake master cylinder reservoir. Remove brake fluid until brake master cylinder reservoir is half full. Discard removed fluid.
2. Raise vehicle.
3. Remove wheel and tire assembly from front disc brake rotor mounting face. Use care to avoid damage or interference with disc brake caliper, front disc brake rotor shield or front wheel knuckle.
4. Remove rear brake pin retainers.
5. Note: It is not necessary to disconnect hydraulic connections.
Lift disc brake caliper from front disc brake caliper anchor plate and front disc brake rotor. Do not pry directly against metal caliper piston or damage will occur.
6. Note: To prevent damage, do not allow disc brake caliper to hang by the front brake hose. Position disc brake caliper out of the way.
7. Remove inner outer brake shoe and lining assembly from front disc brake caliper anchor plate.
8. Inspect both rotor braking surfaces. Minor scoring or buildup of
lining material does not require machining or replacement of front disc
brake rotor. Hand-sand glaze from both rotor braking surfaces using garnet
paper 100A (medium-grit) or aluminum oxide 150-J (medium).
Installation
Note: If front disc brake rotor has been moved relative to the wheel hub and rust or dirt may have shifted between front disc brake rotor and wheel hub, on-vehicle rotor runout can be increased significantly. This can lead to brake shudder. Clean all dirt or foreign material from mating surfaces of caliper loating pins and caliper housing ears. Dirt can cause caliper locating pins to be crooked after rear brake pin retainers are torqued, preventing disc brake caliper from sliding properly.
1. CAUTION: Metal or sharp objects cannot come into direct contact with piston surface or damage will result.
Use a 10 cm (4-inch) C-clamp and a wood block or other flat stock, like an old brake shoe and lining to seat hydraulic caliper piston in its bore. This must be done to provide clearance for disc brake caliper to fit over front disc brake rotor during installation. Extra care must be taken during this procedure to prevent damage to metal caliper piston.
2. Remove all rust buildup from inside of disc brake caliper (shoe contact area).
3. Install inner and outer brake shoe and lining assembly with clip-on insulators into front disc brake caliper anchor plate.
4. Install disc brake caliper as described.
5. Install rear brake pin retainer as described. Tighten to 31-38 N-m (23-28 lb-ft).
6. 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.
Install wheel and tire assembly on vehicle. Tighten lug nuts to 115-142 N-m (85-104 lb-ft) using a torque wrench.
7. Lower vehicle.
8. Pump brake pedal prior to moving vehicle to position brake linings. Refill brake master cylinder with Ford High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or DOT3 equivalent meeting Ford specification ESA-M6C25-A.
9. Road test vehicle.
Removal
1. Raise vehicle.
2. Remove wheel and tire assembly from rotor mounting face. Do not damage wheel cylinder bleeder screw fitting during removal.
3. Disconnect front brake hose from front disc brake caliper. Remove hollow retaining bolt that connects hose fitting to front disc brake caliper. Remove hose assembly from front disc brake caliper and plug hose. Discard copper washers.
4. Remove two rear brake pin retainers.
5. Lift disc brake caliper off front disc brake rotor using rotating motion.
Installation
Note: If front disc brake rotor has been moved relative to the wheel hub (1104) and rust or dirt may have shifted between front disc brake rotor and wheel hub, on-vehicle rotor runout can be increased significantly. This can lead to brake shudder. Clean all dirt or foreign material from mating surfaces of caliper locating pins and caliper housing ears. Dirt can cause caliper locating pins to be crooked after rear brake pin retainers are torqued, preventing disc brake caliper from sliding properly.
1. CAUTION: Do not pry directly against metal piston, or damage to piston will occur.
Retract caliper piston fully in caliper piston bore. Make sure inner and outer shoes are properly positioned in front disc brake caliper anchor plate. Make sure front wheel disc brake shoe insulators are attached to the brake shoe plate. Make sure lining material is facing front disc brake rotor. Position disc brake caliper over front disc brake rotor and brake shoes and linings.
2. Install rear brake pin retainer through front disc brake caliper holes into disc brake caliper locating pins and hand start.
To make sure correct disc brake caliper is installed on correct side of vehicle. The bleeder screw should be positioned on top of disc brake caliper when assembled on vehicle.
3. Tighten two rear brake pin retainers to 31-38 N-m (23-28 lb-ft).
4. Remove plug and install front brake hose on disc brake caliper with new copper washer on each side of fitting outlet. Insert retaining bolt through washers and fitting. Tighten to 41-54 N-m (31-39 lb-ft).
5. Note: Always replace rubber bleed screw cap after bleeding.
Bleed the serviced disc brake caliper.
6. Fill brake master cylinder () with specified brake fluid to MAX line to 4 mm (0.16 inch) below on reservoir. Use High Performance DOT-3 Motor Vehicle Brake Fluid C6AZ-19542-AB or DOT-3 equivalent meeting Ford specification ESA-M6C25-A.
7. 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.
Install wheel and tire assembly on vehicle. Tighten lug nuts to 115-142 N-m (85-104 lb-ft) using a torque wrench.
8. Lower vehicle.
9. Road test vehicle.
Removal
1. Raise vehicle.
2. Remove wheel and tire assembly. Be careful to avoid damage or interference with caliper bleeder screw fitting and front disc brake rotor shield.
3. CAUTION: Handle front disc brake rotor and disc brake caliper assembly in such a way as to prevent deformation of front disc brake rotor, and nicking, scratching or contamination of brake linings/rotor surfaces.
Note: To prevent damage, do not allow disc brake caliper to hang by the front brake hose.
Remove caliper anchor plate bolts and discard. Position disc brake caliper out of the way. Prevent separation of caliper housing from anchor bracket because contamination of guide pin journals can occur.
4. Note: If excessive force must be used during front disc brake rotor removal, the front disc brake rotor should be checked for runout prior to installation.
If additional force is required to remove front disc brake rotor, apply Rust Penetrant and Inhibitor F2AZ-19A501-A or equivalent meeting Ford specification ESR-M99C56-A on front and rear rotor/hub mating surfaces. First, strike front disc brake rotor between lug bolts with a plastic hammer. If this does not work, attach 2-3 Jaw Puller D80L-1013-A or equivalent and remove front disc brake rotor. Remove front disc brake rotor from wheel hub assembly by pulling it off the lug bolts.
Installation
1. If original front disc brake rotor is being installed, make sure rotor braking and mounting surfaces are clean.
2. CAUTION: Failure to clean rust and foreign material from rotor and hub mounting faces when installing new or old front disc brake rotors will result in high rotor runout, which will speed up the development of brake roughness shudder vibration.
Apply a small amount of Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to pilot diameter of front disc brake rotor.
3. Install front disc brake rotor on wheel hub assembly.
4. Install disc brake caliper and new caliper anchor bracket bolts on front disc brake rotor. Tighten caliper anchor bracket bolts to 88-118 N-m (65-87 lb-ft).
5. 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.
Install wheel and tire assembly on vehicle. Tighten lug nuts to 115-142 N-m (85-104 lb-ft) using a torque wrench.
6. Lower vehicle.
7. Pump brake pedal prior to moving vehicle to position brake linings.
8. Road test vehicle.