1991 1999 ford explorer chilton User Manual

							Use a prytool to carefully pry around the edge of the boot ...
... then remove the boot from the caliper housing, taking care not to score or damage the bore
Remove the piston seals from the groove in the caliper bore.
6.  HOW TO USE THIS BOOK
1010 OVERHAUL 
						

							Use extreme caution when removing the piston seal; DO NOT scratch the caliper bore
Carefully loosen the brake bleeder valve cap and valve from the caliper housing.
7. 
Inspect the caliper bores, pistons and mounting threads for scoring or excessive wear.
8. 
Use crocus cloth to polish out light corrosion from the piston and bore.
9. 
Clean all parts with denatured alcohol and dry with compressed air.
10. 
To assemble: Lubricate and install the bleeder valve and cap.
11. 
Install the new seals into the caliper bore grooves, making sure they are not twisted.
12. 
Lubricate the piston bore.
13. 
Install the pistons and boots into the bores of the calipers and push to the bottom of the bores.
14. 
Use a suitable driving tool to seat the boots in the housing.
15. 
Use the proper size driving tool and a mallet to properly seal the boots in the caliper housing
Install the caliper in the vehicle.
16. 
Install the wheel and tire assembly, then carefully lower the vehicle.
17.  HOW TO USE THIS BOOK
OVERHAUL 1011 
						

							Properly bleed the brake system.
18. 
Brake Rotor (Disc)
REMOVAL & INSTALLATION
Except 1995-99 4-Wheel Drive Models Loosen the wheel lug nuts.
1. 
Jack up the front of the vehicle and support on jackstands.
2. 
Remove the wheel and tire.
3. 
On 1991-94 models, remove the brake caliper assembly as described earlier in this Section, but do
not disconnect the brake hose.
4. 
On 1995-99 models, remove the two anchor plate-to-steering knuckle bolts then slide the assembly
off of the rotor.
5. 
Suspend the caliper assembly by a piece of wire. Do not allow it to hang by the brake hose.
6. 
Follow the procedure given under wheel bearing removal in Section 7 for models with manual and
automatic locking hubs.
7. 
New rotor assemblies come protected with an anti-rust coating which should be removed with
denatured alcohol or degreaser. New hubs must be packed with EP wheel bearing grease.
Installation is the reverse of the removal procedure.
8. 
1995-99 4-Wheel Drive Models Loosen the wheel lug nuts.
1. 
Jack up the front of the vehicle and support on jackstands.
2. 
Remove the wheel and tire.
3. 
Remove the two anchor plate-to-steering knuckle bolts then slide the assembly off of the rotor.
4. 
Grasp the rotor and pull it from the wheel hub. Some models may have a small retaining screw
holding the rotor to the wheel hub, if so, remove the screw then pull the rotor off.
5. 
Installation is the reverse of the removal procedure.
6. 
INSPECTION HOW TO USE THIS BOOK
1012 Brake Rotor (Disc) 
						

							Disc brake service limits
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Inspect the rotor for cracks, grooves or waviness. Rotors that arent too badly scored or grooved can
be resurfaced by most automotive shops.
1. 
Measure the rotor thickness using a caliper gauge.
2. 
Minimum rotor thickness should be 0.81 in. (20.5mm). If refinishing exceeds that, the rotor will have
to be replaced.
3. 
Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. HOW TO USE THIS BOOK
INSPECTION 1013 
						

							
REAR DRUM BRAKES
Introduction
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REAR DRUM BRAKES 1015 
						

							Component locations on the left side 10 in. brake assembly
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HOW TO USE THIS BOOK
1016 Introduction 
						

							Component locations on the right side 10 in. brake assembly
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Brake Drums
REMOVAL & INSTALLATION CAUTION
Older brake pads or shoes may contain asbestos, which has been determined to be a cancer causing agent.
Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When
cleaning brake surfaces, use a commercially available brake cleaning fluid.
Raise the vehicle so that the wheel to be worked on is clear of the floor and install jackstands under
the vehicle.
1.  HOW TO USE THIS BOOK
Brake Drums 1017 
						

							To remove the rear brake drum, first safely raise the rear of the vehicle and remove the wheel ...
Remove the hub cap and the wheel/tire assembly. Remove the 3 retaining nuts and remove the brake
drum. It may be necessary to back off the brake shoe adjustment in order to remove the brake drum.
This is because the drum might be grooved or worn from being in service for an extended period of
time.
2. 
... then grasp hold of the drum and pull it from the axle flange and brake shoes
Before installing a new brake drum, be sure and remove any protective coating with carburetor
degreaser.
3. 
Install the brake drum in the reverse order of removal and adjusts the brakes.
4. 
INSPECTION HOW TO USE THIS BOOK
1018 REMOVAL & INSTALLATION 
						

							Drum brake service limits. The maximum inside diameter is cast into the drum
Click to enlarge
After the brake drum has been removed from the vehicle, it should be inspected for run-out, severe scoring
cracks, and the proper inside diameter.
Minor scores on a brake drum can be removed with fine emery cloth, provided that all grit is removed from
the drum before it is installed on the vehicle.
A badly scored, rough, or out-of-round (run-out) drum can be ground or turned on a brake drum lathe. Do
not remove any more material from the drum than is necessary to provide a smooth surface for the brake shoe
to contact. The maximum diameter of the braking surface is shown on the inside of each brake drum. Brake
drums that exceed the maximum braking surface diameter shown on the brake drum, either through wear or
refinishing, must be replaced. This is because after the outside wall of the brake drum reaches a certain
thickness (thinner than the original thickness) the drum loses its ability to dissipate the heat created by the
friction between the brake drum and the brake shoes, when the brakes are applied. Also the brake drum will
have more tendency to warp and/or crack.
The maximum braking surface diameter specification, which is shown on each drum, allows for a 0.060 in.
(1.5mm) machining cut over the original nominal drum diameter plus 0.030 in. (0.76mm) additional wear
before reaching the diameter where the drum must be discarded. Use a brake drum micrometer to measure the
inside diameter of the brake drums.
Brake Shoes
REMOVAL & INSTALLATION CAUTION
Older brake pads or shoes may contain asbestos, which has been determined to be a cancer causing agent.
Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When
cleaning brake surfaces, use a commercially available brake cleaning fluid. HOW TO USE THIS BOOK
INSPECTION 1019 
						

							Raise and support the vehicle and remove the wheel and brake drum from the wheel to be worked on.
1. 
If you have never replaced the brakes on a car before and you are not too familiar with the procedures
involved, only disassemble and assemble one side at a time, leaving the other side intact as a reference
during reassembly.
Install a clamp over the ends of the wheel cylinder to prevent the pistons of the wheel cylinder from
coming out, causing loss of fluid.
2. 
Contract the brake shoes by pulling the self-adjusting lever away from the starwheel adjustment
screw and turn the starwheel up and back until the pivot nut is drawn onto the starwheel as far as it
will come.
3. 
Clean the brake shoe assemblies with a liquid cleaning solution, NEVER with compressed air To begin remove the brake shoes, pull the adjuster cable towards the shoe ... HOW TO USE THIS BOOK
1020 REMOVAL & INSTALLATION