REMOVAL & INSTALLATION
Floating Caliper Disc Brakes
See Figures 1, 2, 3, 4, 5 and 6
- Raise the vehicle on a hoist, place on jackstands, and remove the front wheels.
- Remove the lockwires from the two mounting bolts. Remove the mounting bolts and lift the caliper away from the disc. Support the caliper with a coat hanger or other piece of wire.
- Remove the retaining clips with a suitable prytool and slide the outboard pad and retaining pins out of the caliper. Remove the inboard pad.
- Use a C-clamp or other suitable to compress the caliper piston back into the caliper bore.
- Slide the new inboard pad into the caliper so that the tabs are between the retaining clips and anchor plate and the backing plate lies flush against the piston.
- Insert the inboard pad retaining pins into the outboard pad and position them in the caliper.
Stabilizer, insulator, pad clips, and pins should always be replaced when the disc pads are replaced.
- Hold the retaining pins in place (one at a time) with a short drift pin or dowel and install the retaining clips.
- Slide the caliper assembly over the disc and align the mounting bolt holes.
- Install the lower bolt finger-tight. Install the upper bolt and tighten. Secure the lower bolt. Safety-wire both bolts. The torque specifications are: Upper anchor plate mounting bolt 125 ft. lbs. (169 Nm) and lower anchor plate mounting bolt 105 ft. lbs. (142 Nm). The caliper mounting bolts 25-35 ft. lbs. (34-47 Nm).
Do not deviate from this procedure. The alignment of the anchor plate depends on the proper sequence of bolt installation.
- Check the brake fluid level and pump and brake pedal to seat the lining against the disc. Adjust the rear brakes if necessary. Replace the wheels and road-test the vehicle.
See Figures 7 through 19
- Remove approximately 2 / 3 of the fluid from the rear reservoir of the tandem master cylinder. Raise and support the vehicle, taking proper safety precautions.
- Remove the wheel and tire assembly.
- Remove the key retaining screw from the caliper retaining key.
- Slide the retaining key and support spring either inward or outward from the anchor plate. To remove the key and spring, a hammer and drift may be used, taking care not to damage the key in the process.
- Lift the caliper assembly away from the anchor plate by pushing the caliper downward against the anchor plate and rotating the upper end upward out of the anchor plate. Be careful not to stretch or twist the flexible brake hose.
- Remove the inner shoe and lining assembly from the anchor plate. The inner shoe anti-rattle clip may become displaced at this time and should be repositioned on the anchor plate. Lightly tap on the outer shoe and lining assembly to free it from the caliper.
- Clean the caliper, anchor plate, and disc assemblies, and inspect them for brake fluid leakage, excessive wear or signs of damage. Replace the pads if either of them are worn to within 1 / 32 in. (0.8mm) of the rivet heads.
- To install new pads, use a 4 in. (10cm) C-clamp and a block of wood 1 in. (25mm) and approximately 3 / 4 in. (19mm) thick to seat the caliper hydraulic piston in its bore. This must be done in order to provide clearance for the caliper to fit over the rotor when new linings are installed.
- At this point, the anti-rattle clip should be in its place on the lower inner brake shoe support of the anchor plate with the pigtail of the clip toward the inside of the anchor plate. Position the inner brake shoe and lining assembly on the anchor plate with the pad toward the disc.
- Install the outer brake shoe with the lower flange ends against the caliper leg abutments and the brake shoe upper flanges over the shoulders on the caliper legs. The shoe is installed correctly when its flanges fit snugly against the machined surfaces of the shoulders.
- Remove the C-clamps used to seat the caliper piston in its bore. The piston will remain seated.
- Position the caliper housing lower V-groove on the anchor place lower abutment surface.
- Pivot the caliper housing upward toward the disc until the outer edge of the piston dust boot is about 1 / 4 in. (6mm) from the upper edge of the inboard pad.
- In order to prevent pinching of the dust boot between the piston and the inboard pad during installation of the caliper, place a clean piece of thin cardboard between the inboard pad and the lower half of the piston dust boot.
- Rotate the caliper housing toward the disc until a slight resistance is felt. At this point, pull the cardboard downward toward the disc centerline while rotating the caliper over the disc. Then remove the cardboard and complete the rotation of the caliper down over the disc
- Slide the caliper up against the upper abutment surfaces of the anchor plate and center the caliper over the lower anchor plate abutment.
- Position the caliper support spring and key in the key slot and slide them into the opening between the lower end of the caliper and the lower anchor plate abutment until the key semicircular slot is centered over the retaining screw threaded hole in the anchor plate.
- Install the key retaining screw and tighten to 12-16 ft. lbs. (16-22 Nm).
- Check the fluid level in the master cylinder and fill as necessary. Install the reservoir cover. Depress the brake pedal several times to properly seat the caliper and pads. Check for leakage around the caliper and pads. Check for leakage around the caliper and flexible brake hose.
- Install the wheel and tire assembly and tighten the nuts to 70-115 ft. lbs. (94-154 Nm). Install the wheel cover.
- Adjust the rear brakes and lower the car. Make sure that you obtain a firm brake pedal and then road test the car for proper brake operation.
See Figures 7 through 19
Ford recommends that the plastic sleeves and the caliper locating insulators be replaced when the brake pads are replaced.
- Remove the master cylinder cap, and check the fluid level in the primary (large) reservoir. Remove brake fluid until the reservoir is half full. Properly discard this fluid.
- Raise and safely support the vehicle. Remove the wheel and tire assembly from the hub. Be careful to avoid damage to or interference with the caliper splash shield or bleeder screw fitting.
- Remove the caliper locating pins.
- Lift the caliper assembly from the integral spindle/anchor plate and rotor.
- Remove the inner shoe and lining assembly. Inspect both rotor braking surfaces. Minor scoring or building of lining material does not require machining or replacement of the rotor.
- Suspend the caliper inside the fender housing with a wire hooked through the outer leg hole of the caliper. Be careful not to damage the caliper or stretch the brake hose.
- Remove and discard the plastic sleeves that are located inside the caliper locating pin insulators. These parts must not be reused.
- Remove and discard the caliper locating insulator. These parts must not be reused.
- Use a 4 in. (10cm) C-clamp and a block of wood 1 in. (25mm) and approximately 3 / 4 in. (19mm) thick to seat the caliper hydraulic piston in its bore. This must be done to provide clearance for the caliper assembly to fit over the rotor when installed. Remove the C-clamp from the caliper (the caliper piston will remain seated in its bore).
- Install new locating pin insulators. Tighten evenly to 45-60 ft. lbs. (61-81 Nm) and plastic sleeves in the caliper housing. Do not use a sharp edge tool to insert the insulators in the caliper housing. Check to see if both insulator flanges straddle the housing holes and if the plastic sleeves are bottomed in the insulators as well as slipped under the upper lip.
- Install the correct inner shoe and lining assembly in the caliper piston. All vehicles have a separate anti-rattle clip and insulator that must be installed to the inner shoe and lining prior to their assembly to the caliper. The inner shoes are marked LH or RH and must be installed in the proper caliper. Also, care should be taken not to bend the anti-rattle clips too far in the piston or distortion and rattles can result.
- Install the correct outer brake shoe and lining assembly (RH/LH), making sure that the clip and/or buttons located on the shoe are properly seated. The outer shoe can be identified as right-hand or left-hand by the wear indicator which must always be installed toward the front of the vehicle or by a LH or RH mark. Refill the master cylinder.
- Adjust the rear brakes. Install the wheel and tire assembly.
- Pump the brake pedal prior to moving the vehicle to position the brake linings. Road test the vehicle.