INSPECTION
Replace the front pads when the pad thickness is at the minimum thickness recommended by the Ford Motor Co. which is 1 / 32 in. (0.1mm), or at the minimum allowed by the applicable state or local motor vehicle inspection code. Pad thickness may be checked by removing the wheel and looking through the inspection port in the caliper assembly.
REMOVAL & INSTALLATION
Single Piston Caliper
See Figures 1 through 19
Ford recommends that new caliper pins be installed whenever the caliper is removed from the steering knuckle.
- To avoid fluid overflow when the caliper piston is pressed into the caliper cylinder bores, remove or siphon part of the brake fluid out of the master cylinder reservoir (connected to the front disc brakes). Discard the removed fluid.
- Loosen the wheel lug nuts.
- Raise the vehicle and install jackstands. Remove a front wheel and tire assembly.
- Place an 1 in. (133mm) C-clamp on the caliper and tighten the clamp slightly to push the caliper piston in its bore. This will ease caliper removal from the rotor. Remove the clamp.
Do not use a screwdriver or similar tool to pry piston away from the rotor.
- There are 3 types of caliper pins used: a single tang type, a double tang type and a split-shell type. The pin removal process is dependent upon how the pin is installed (bolt head direction). Remove the upper caliper pin first.
On some applications, the pin may be retained by a nut and Torx® head bolt (except the split-shell type).
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If the bolt head is on the outside of the caliper, use the following procedure:
- From the inner side of the caliper, tap the bolt within the caliper pin until the bolt head on the outer side of the caliper shows a separation between the bolt head and the caliper pin.
- Using a hacksaw or bolt cutter, remove the bolt head from the bolt.
- Depress the tab on the bolt head end of the upper caliper pin with a screwdriver, while tapping on the pin with a hammer. Continue tapping until the tab is depressed by the V-slot.
- Place one end of a punch, 1 / 2 in. (6mm) or smaller, against the end of the caliper pin and drive the caliper pin out of the caliper toward the inside of the vehicle. Do not use a screwdriver or other edged tool to help drive out the caliper pin as the V-grooves may be damage.
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If the nut end of the bolt is on the outside of the caliper, use the following procedure:
- Remove the nut from the bolt.
- Depress the lead tang on the end of the upper caliper pin with a screwdriver while tapping on the pin with a hammer. Continue tapping until the lead tang is depressed by the V-slot.
- Place one end of a punch, 1 / 2 in. (6mm) or smaller, against the end of the caliper pin and drive the caliper pin out of the caliper toward the inside of the vehicle. Do not use a screwdriver or other edged tool to help drive out the caliper pin as the V-grooves may be damaged.
- Repeat the procedure in Step 4 for the lower caliper pin.
Fig. Fig. 1: Before beginning the brake pad procedure, remove some fluid from the master cylinder
Fig. Fig. 2: Two styles of caliper pins used, single tang pin is similar to the double tang
Fig. Fig. 3: View of a caliper pin with the bolt head facing the outside of the caliper
Fig. Fig. 4: Use a hacksaw to remove the bolt head from the pin
Fig. Fig. 5: View of a caliper pin with the nut facing the outside of the caliper
Fig. Fig. 6: Use a hammer and punch, and drive the caliper pin out from between the caliper and its mount
Fig. Fig. 7: When removing the pin, you may need to depress the pin tab with a tool
Fig. Fig. 8: Pull the out from behind the caliper. Repeat the procedure for the lower pin
- Remove the caliper from the rotor.
- Remove the outer pad. Remove the anti-rattle clips and remove the inner pad.
- Place the inner pads friction material against the caliper piston and assemble the C-clamp to the caliper again. Tighten the clamp until the caliper piston is fully seated into its bore.
Fig. Fig. 9: Slide the caliper assembly off of the rotor
Fig. Fig. 10: Holding the caliper as shown, press down then slide the pad out to remove it from the caliper
Fig. Fig. 11: Remove the outer brake pad from the caliper
Fig. Fig. 12: If necessary, support the caliper by a length of wire from the frame. Never let it hang by the hose
Fig. Fig. 13: Finally, remove the inner brake pad from the steering knuckle assembly
Fig. Fig. 14: Place the inner pad's friction material against the caliper piston and press it in with a C-clamp
Fig. Fig. 15: Ensure that the anti-rattle clip is installed as shown on the inner pad
Fig. Fig. 16: View of a correctly installed outer pad
Fig. Fig. 17: Install the upper caliper pin with the tang facing up-tangs are installed facing down on the bottom pin
Fig. Fig. 18: Ensure that the tang is driven flush to the caliper mount
Fig. Fig. 19: After installing the pins, ensure that the tangs are free to contact either side of the caliper mount
- Place a new anti-rattle clip on the lower end of the inner pad. Be sure the tabs on the clip are positioned properly and the clip is fully seated.
- Position the inner pads and anti-rattle clip in the abutment with the anti-rattle clip tab against the pad abutment and the loop-type spring away from the rotor. Compress the anti-rattle clip and slide the upper end of the pad in position.
- Install the outer pad, making sure the torque buttons on the pad spring clip are seated solidly in the matching holes in the caliper.
- Install the caliper on the spindle, making sure the mounting surfaces are free of dirt and lubricate the caliper grooves with Disc Brake Caliper Grease. Install new caliper pins, making sure the pins are installed with the tang in position as shown. The pin must be installed with the lead tang in first, the bolt head facing outward (if equipped) and the pin positioned as shown. Position the lead tang in the V-slot mounting surface and drive in the caliper until the drive tang is flush with the caliper assembly. Install the nut (if equipped) and tighten to 32-47 inch lbs.
- Install the wheel and tire assembly.
- Remove the jackstands and lower the vehicle. Torque the lug nuts to 30 ft. lbs. (65 Nm).
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.
- Check the brake fluid level and fill as necessary. Check the brakes for proper operation before driving the vehicle.
See Figures 20, 21 and 22
Fig. Fig. 20: Exploded view of the 4x4 Ranger front brake caliper assembly-4x2 Ranger similar
Fig. Fig. 21: Exploded view of the 4x4 Explorer/Mountaineer front brake caliper assembly-4x2 models similar
Fig. Fig. 22: Use a C-clamp to slightly press in the caliper piston to aid removal
- To avoid fluid overflow when the caliper piston is pressed into the caliper cylinder bores, remove or siphon part of the brake fluid out of the master cylinder reservoir (connected to the front disc brakes). Discard the removed fluid.
- Loosen the wheel lug nuts.
- Raise and safely support the front of the vehicle. Remove the wheel.
- Place an 1 in. (133mm) C-clamp on the caliper and tighten the clamp to bottom the caliper pistons in their bores. Remove the clamp.
- Remove the two caliper slide pin bolts and lift the caliper from the anchor plate.
Use care to retain as much of the original caliper slide pin grease as possible.
- Position the caliper on a frame member or suspend it with some wire. Do not allow the caliper to hang by the brake hose.
- Remove the brake pads and, if necessary, the anti-rattle clips from the anchor plate.
- Remove the shims, if any, from the brake pads for re-use.
- If removed, install the anti-rattle clips.
- Install the brake pads to the anchor plate.
- Position the caliper over the brake pads and align the slide pin mounting holes.
- Install the slide pin bolts and tighten them to 14-26 ft. lbs. (30-36 Nm).
- Install the wheel and snug the lug nuts.
- Lower the vehicle and tighten the lug nuts to 30 ft. lbs. (65 Nm).
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.
- Start the engine and apply the brakes several times to readjust the caliper pistons. Ensure that the pedal feels firm before operating the vehicle.
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