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    Lincoln Aviator, Ford Explorer, Exp Sport, Exp Sport-Trac, Mercury Mountaineer 2000-2005

    Brake Caliper

    Print

    Removal & Installation



    1. Before servicing the vehicle, please familiarize yourself with safety procedures.
    2.  
    3. Loosen the wheel lug nuts.
    4.  
    5. Raise and safely support the front of the vehicle. Remove the wheel.
    6.  
    7. Place an 8 in. (203mm) C-clamp on the caliper and tighten the clamp to bottom the caliper pistons in their bores. Remove the clamp.
    8.  
    9. Remove the two caliper slide pin bolts and lift the caliper from the anchor plate.
      NOTE
      Use care to retain as much of the original caliper slide pin grease as possible.

    10.  
    11. Position the caliper on a frame member or suspend it with some wire. Do not allow the caliper to hang by the brake hose.
    12.  
    13. Disconnect and plug the brake hose at the caliper. Remove the caliper from the rotor.

      Click image to see an enlarged view

      Fig. Front brake components-Aviator

    14.  

    To install:

    1. Position the caliper over the brake pads and align the slide pin mounting holes.
    2.  
    3. Install the slide pin bolts and tighten them to 32 ft. lbs. (44 Nm).
      NOTE
      Tighten the bottom locator pin caliper bolt before tightening the top guide pin caliper bolt.

    4.  
    5. Install the caliper brake hose using new washers. Tighten the bolt to 26 ft. lbs. (35 Nm).
    6.  
    7. Install the wheel and snug the lug nuts.
    8.  
    9. Lower the vehicle and tighten the lug nuts to 100 ft. lbs. (135 Nm).
      NOTE
      The first couple of times you apply the brakes, the pedal may go to the floor. Continue to pump the brake pedal until it feels firm.

    10.  
    11. Start the engine and apply the brakes several times to readjust the caliper pistons. Ensure that the pedal feels firm before operating the vehicle.
    12.  

    1. Before servicing the vehicle, please familiarize yourself with safety procedures.
    2.  
    3. Loosen the wheel lug nuts.
    4.  
    5. Raise and safely support the front of the vehicle. Remove the wheel.
    6.  
    7. Place an 8 in. (203mm) C-clamp on the caliper and tighten the clamp to bottom the caliper pistons in their bores. Remove the clamp.
    8.  
    9. Remove the two caliper slide pin bolts and lift the caliper from the anchor plate.
      NOTE
      Use care to retain as much of the original caliper slide pin grease as possible.

    10.  
    11. Position the caliper on a frame member or suspend it with some wire. Do not allow the caliper to hang by the brake hose.
    12.  
    13. Disconnect and plug the brake hose at the caliper. Remove the caliper from the rotor.

      Click image to see an enlarged view

      Fig. Front brake components-2002 Explorer and Mountaineer



      Click image to see an enlarged view

      Fig. Front brake components-2-wheel drive Explorer Sport and Sport-Trac



      Click image to see an enlarged view

      Fig. Front brake components-4-wheel drive Explorer Sport and Sport-Trac



      Click image to see an enlarged view

      Fig. Front brake components-2003-05 Explorer and Mountaineer

    14.  

    To install:

    1. Position the caliper over the brake pads and align the slide pin mounting holes.
    2.  
    3. Install the slide pin bolts and tighten them to 24 ft. lbs. (32 Nm).
    4.  
    5. Install the caliper brake hose using new washers. Tighten the bolt to 26 ft. lbs. (35 Nm).
    6.  
    7. Install the wheel and snug the lug nuts.
    8.  
    9. Lower the vehicle and tighten the lug nuts to 100 ft. lbs. (135 Nm).
      NOTE
      The first couple of times you apply the brakes, the pedal may go to the floor. Continue to pump the brake pedal until it feels firm.

    10.  
    11. Start the engine and apply the brakes several times to readjust the caliper pistons. Ensure that the pedal feels firm before operating the vehicle.
    12.  

    1. Before servicing the vehicle, refer to the -Precautions- section and the -Brake Service Precautions- section.
    2.  
    3. Loosen the wheel lug nuts.
    4.  
    5. Raise and safely support the front of the vehicle. Remove the wheel.
    6.  
    7. Place an 8 in. (203mm) C-clamp on the caliper and tighten the clamp to bottom the caliper pistons in their bores. Remove the clamp.
    8.  
    9. Remove the two caliper slide pin bolts and lift the caliper from the anchor plate.
      NOTE
      Use care to retain as much of the original caliper slide pin grease as possible.

    10.  
    11. Position the caliper on a frame member or suspend it with some wire. Do not allow the caliper to hang by the brake hose.
    12.  
    13. Disconnect and plug the brake hose at the caliper. Remove the caliper from the rotor.

      Click image to see an enlarged view

      Fig. Front brake components-Aviator

    14.  

    To install:

    1. Position the caliper over the brake pads and align the slide pin mounting holes.
    2.  
    3. Install the slide pin bolts and tighten them to 32 ft. lbs. (44 Nm).
      NOTE
      Tighten the bottom locator pin caliper bolt before tightening the top guide pin caliper bolt.

    4.  
    5. Install the caliper brake hose using new washers. Tighten the bolt to 26 ft. lbs. (35 Nm).
    6.  
    7. Install the wheel and snug the lug nuts.
    8.  
    9. Lower the vehicle and tighten the lug nuts to 100 ft. lbs. (135 Nm).
      NOTE
      The first couple of times you apply the brakes, the pedal may go to the floor. Continue to pump the brake pedal until it feels firm.

    10.  
    11. Start the engine and apply the brakes several times to readjust the caliper pistons. Ensure that the pedal feels firm before operating the vehicle.
    12.  

    1. Before servicing the vehicle, refer to the -Precautions- section and the -Brake Service Precautions- section.
    2.  
    3. Loosen the wheel lug nuts.
    4.  
    5. Raise and safely support the front of the vehicle. Remove the wheel.
    6.  
    7. Place an 8 in. (203mm) C-clamp on the caliper and tighten the clamp to bottom the caliper pistons in their bores. Remove the clamp.
    8.  
    9. Remove the two caliper slide pin bolts and lift the caliper from the anchor plate.
      NOTE
      Use care to retain as much of the original caliper slide pin grease as possible.

    10.  
    11. Position the caliper on a frame member or suspend it with some wire. Do not allow the caliper to hang by the brake hose.
    12.  
    13. Disconnect and plug the brake hose at the caliper. Remove the caliper from the rotor.

      Click image to see an enlarged view

      Fig. Front brake components-2005 2WD Explorer Sport-Trac



      Click image to see an enlarged view

      Fig. Front brake components-2005 4WD Explorer Sport-Trac



      Click image to see an enlarged view

      Fig. Front brake components-2005 Explorer and Mountaineer

    14.  

    To install:

    1. Position the caliper over the brake pads and align the slide pin mounting holes.
    2.  
    3. Install the slide pin bolts and tighten them to 24 ft. lbs. (32 Nm).
    4.  
    5. Install the caliper brake hose using new washers. Tighten the bolt to 26 ft. lbs. (35 Nm).
    6.  
    7. Install the wheel and snug the lug nuts.
    8.  
    9. Lower the vehicle and tighten the lug nuts to 100 ft. lbs. (135 Nm).
      NOTE
      The first couple of times you apply the brakes, the pedal may go to the floor. Continue to pump the brake pedal until it feels firm.

    10.  
    11. Start the engine and apply the brakes several times to readjust the caliper pistons. Ensure that the pedal feels firm before operating the vehicle.
    12.  

     
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