Removal & Installation
The front disc brake caliper slides on 2 stainless steel locating pins. The front disc brakes use a conventional pin slider-type front disc brake caliper with a 10.875 inch (27.6cm) front disc rotor. The front disc brake caliper is attached to the front suspension with 2 Torx® head brake caliper bolts. Rubber insulators isolate the stainless steel locating pins from direct contact with the front disc brake caliper. The front disc brake calipers must be removed to replace the front brake pads.
- Before servicing the vehicle, refer to the Precautions section.
Remove or disconnect the following:
NOTEIf the brake caliper is being removed for brake pad replacement only, DO NOT disconnect the brake hose.
Wheel and tire
2 caliper pin bolts. Most applications will require a Torx® T-40 bit to remove the 2 brake caliper bolts.
If the brake caliper is being removed just for brake service, with the brake hose still attached to the caliper, use a length of wire to support the caliper from the front shock absorber. Do not let the caliper hang by the brake hose. If the caliper is being completely removed from the vehicle for overhaul, use care not to drip brake fluid on the paint.
NOTEIf both calipers are being completely removed from the vehicle at the same time, mark them Left and Right so the calipers can be reinstalled to their original locations. The reason for this is that the bleeder screws must be positioned on the top of the front disc brake caliper when installed on the vehicle.
- Clean all parts well. Use a C-clamp and a used brake pad to push the caliper piston fully in the piston bore. Inspect the caliper pins and clean any dirt and debris.
- Install the caliper onto the rotor. Make sure the inboard and outboard brake pads are properly positioned.
- Lubricate the stainless steel locating pins with a Silicone Dielectric Compound such as Ford DZAZ-19A331-A or equivalent silicone grease. Install the 2 caliper pin bolts and torque to 18-25 ft. lbs. (24-34 Nm).
- If disconnected, install the brake hose using a new replacement copper washer, install the banjo bolt and torque to 12-14 ft. lbs. (17-20 Nm).
- If the brake hose had been disconnected, bleed the brake system.
- Install the wheel and tire.
- Torque the lug nuts to 72-87 ft. lbs. (98-118 Nm).
- Check the master cylinder reservoir and add fresh DOT 3 brake fluid as required.
- Lower the vehicle. Pump the brake pedal slowly until a firm brake pedal is obtained, indicating that the brake pads are properly seated, before attempting to move the vehicle. Road-test and check for proper brake operation.
- Loosen the lug nuts on the front wheels.
- Apply the parking brake, block the rear wheels, then raise and safely support the front of the vehicle securely on jackstands.
- Remove the front wheels.
- Disconnect the brake flex hose from the caliper by removing the banjo bolt and copper washer. Discard the washer.
- Using a Torx ® T-40 bit, remove the two caliper bolts.
- Lift the caliper and brake pad assembly from the rotor using a rotating motion.
- Make sure that the caliper piston is fully seated. If not, use a large C-clamp placed on a used inboard brake pad or wood block to compress the caliper piston.
- Install the inboard pad in the caliper piston. Install the outboard pad, making sure that the clips are properly seated.
- Position the caliper on the rotor.
- Lubricate the caliper bolts with a silicone dielectric compound such as Ford D7AZ-19A331-A or equivalent silicone grease. Install the two caliper bolts and tighten them to 18 - 25 ft. lbs. (24 - 34 Nm).
- Install the brake flex hose using a new copper washer. Tighten the banjo bolt to 30 - 45 ft. lbs. (40 - 60 Nm).
- Fill the master cylinder reservoir, as necessary, using only new DOT 3 or equivalent brake fluid.
- Properly bleed the brake system. Please refer to Bleeding the Brake System for the procedure.
- Install the wheels. Tighten the lug nuts to 72 - 87 ft. lbs. (98 - 118 Nm).
- Pump the brake pedal several times prior to moving the vehicle to position the brake pads to the rotor.
- Refill the master cylinder reservoir as necessary, using only new DOT 3 or equivalent brake fluid.
- Road test the vehicle and check the brake system for proper operation.