Ford Freestar, Monterey 2004-2006

Brake Pads

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Removal & Installation



  1. Remove 1 / 2 of the brake fluid from the brake master cylinder reservoir. Properly dispose of the brake fluid.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the wheel and tire assembly.
  6.  
  7. Using a C-clamp or equivalent, position the clamp frame on the inboard side of the disc brake caliper housing. Place the clamp screw on the outboard disc brake pad and tighten the clamp enough to press the caliper piston into the caliper housing releasing pressure on the disc brake pads.
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  9. Remove 2 disc brake caliper retaining bolts. Do not remove the disc brake caliper brake hose from the caliper.
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  11. Work the disc brake caliper off the brake rotor and disc brake adapter. Move the disc brake caliper aside and secure with wire or equivalent to prevent damage to the brake hose.
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  13. Remove the slippers from the anchor plate abutments by gently prying them off the rails and discard the slippers.
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  15. Remove the inner and outer disc brake pads.
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  17. Inspect the disc brake rotor surfaces for grooves, cracks or glazing. Resurface or replace as required. If resurfacing, observe the minimum thickness specification.
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To install:

  1. Retract the disc brake caliper piston fully into the caliper bore using a C-clamp and block of wood or equivalent. This will make room for the new disc brake pads.
  2.  
  3. Install new anti-wear slippers on the rail abutments by snapping them in place.
  4.  
  5. Install new inner and outer disc brake pads. Ensure that the disc brake pads are properly positioned and that the lining material is facing the rotor.
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  7. Install the disc brake caliper over the brake rotor and place on the brake adapter. Ensure that the notches on the upper ends of the brake pads are seated over the upper ledge of the disc brake adapter and the lower tabs are placed on the lower ledge of the disc brake adapter.
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  9. Lubricate 2 disc brake caliper retaining bolts with a suitable grease and install. Tighten the retaining bolts to 41ft. lbs. (55 Nm).
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  11. Install the wheel and tire assembly. Torque the lug nuts to 100 ft. lbs. (136 Nm).
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  13. Lower the vehicle.
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  15. Pump the brake pedal several times to position the brake pads before attempting to move the vehicle.
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  17. Check and fill the brake master cylinder reservoir, as required.
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  19. Road-test the vehicle and check for proper brake operation.
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