1991 1999 ford explorer chilton User Manual

							Adjusting the rear brakes
Click to enlarge
Adjust the rear brakes with a flat bladed tool inserted in the access hole in the backing plate
The drum brakes are self-adjusting and require a manual adjustment only after the brake shoes have been
replaced.
Disc brakes are not adjustable.
To adjust the rear brakes with drums installed, follow the procedure given below: Raise the vehicle and support it with safety stands.
1. 
Remove the rubber plug from the adjusting slot on the backing plate.
2. 
Turn the adjusting screw using a Brake Shoe Adjustment Tool or equivalent inside the hole to expand
the brake shoes until they drag against the brake drum and lock the drum.
3. 
Insert a small screwdriver or piece of firm wire (coat hanger wire) into the adjusting slot and push the
automatic adjusting lever out and free of the starwheel on the adjusting screw and hold it there.
4. 
Engage the topmost tooth possible on the starwheel with the brake adjusting spoon. Move the end of
the adjusting spoon upward to move the adjusting screw starwheel downward and contract the
adjusting screw. Back off the adjusting screw starwheel until the wheel spins FREELY with a
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ADJUSTMENTS 1031 
						

							minimum of drag about 10 to 12 notches. Keep track of the number of turns that the starwheel is
backed off, or the number of strokes taken with the brake adjusting spoon.
Repeat this operation for the other side. When backing off the brakes on the other side, the starwheel
adjuster must be backed off the same number of turns to prevent side-to-side brake pull.
6. 
When all drum brakes are adjusted, remove the safety stands and lower the vehicle and make several
stops while backing the vehicle, to equalize the brakes at all of the wheels.
7. 
Road test the vehicle. PERFORM THE ROAD TEST ONLY WHEN THE BRAKES WILL APPLY
AND THE VEHICLE CAN BE STOPPED SAFELY!
8. 
Wheel Cylinders
REMOVAL & INSTALLATION To remove the wheel cylinder, jack up the vehicle and remove the wheel, hub, and drum.
1. 
Remove the brake shoe assemblies.
2. 
Remove the brake shoes and the brake line, then remove the bolts and tilt the cylinder inwards ... ... then lift it up and off of the backing plate
Disconnect the brake line at the fitting on the brake backing plate.
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1032 Wheel Cylinders 
						

							Remove the screws that hold the wheel cylinder to the backing plate and remove the wheel cylinder
from the vehicle.
4. 
Installation is the reverse of the above removal procedure. After installation bleed and adjust the
brakes as described earlier in this Section.
5. 
OVERHAUL
Wheel cylinder overhaul kits may be available, but often at little or no savings over a reconditioned wheel
cylinder. It often makes sense with these components to substitute a new or reconditioned part instead of
attempting an overhaul.
If no replacement is available, or you would prefer to overhaul your wheel cylinders, the following procedure
may be used. When rebuilding and installing wheel cylinders, avoid getting any contaminants into the system.
Always use clean, new, high quality brake fluid. If dirty or improper fluid has been used, it will be necessary
to drain the entire system, flush the system with proper brake fluid, replace all rubber components, then refill
and bleed the system.
Remove the wheel cylinder from the vehicle and place on a clean workbench.
1. 
First remove and discard the old rubber boots, then withdraw the pistons. Piston cylinders are
equipped with seals and a spring assembly, all located behind the pistons in the cylinder bore.
2. 
Remove the outer boots from the wheel cylinder
Remove the remaining inner components, seals and spring assembly. Compressed air may be useful in
removing these components. If no compressed air is available, be VERY careful not to score the
wheel cylinder bore when removing parts from it. Discard all components for which replacements
were supplied in the rebuild kit.
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REMOVAL & INSTALLATION 1033 
						

							Compressed air can be used to remove the pistons and seals
Remove the pistons, cup seals and spring from the cylinder
Wash the cylinder and metal parts in denatured alcohol or clean brake fluid.
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1034 OVERHAUL 
						

							Use brake fluid and a soft brush to clean the pistons ...
... and the bore of the wheel cylinder WARNING
Never use a mineral-based solvent such as gasoline, kerosene or paint thinner for cleaning purposes. These
solvents will swell rubber components and quickly deteriorate them.
Allow the parts to air dry or use compressed air. Do not use rags for cleaning, since lint will remain in
the cylinder bore.
5. 
Inspect the piston and replace it if it shows scratches.
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OVERHAUL 1035 
						

							Once cleaned and inspected, the wheel cylinder is ready for assembly
Lubricate the cylinder bore and seals using clean brake fluid.
7. 
Position the spring assembly.
8. 
Install the inner seals, then the pistons.
9. 
Lubricate the cup seals with brake fluidHOW TO USE THIS BOOK
1036 OVERHAUL 
						

							Install the spring, then the cup seals in the bore
Lightly lubricate the pistons, then install them
Insert the new boots into the counterbores by hand. Do not lubricate the boots.
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OVERHAUL 1037 
						

							The boots can now be installed over the wheel cylinder ends
Install the wheel cylinder.
11. 
Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. HOW TO USE THIS BOOK
1038 OVERHAUL 
						

							
REAR DISC BRAKES
General Information
Rear disc brakes were used on all Mountaineers and 1995-99 Explorers.
The system utilizes a drum-in-hat type rear brake rotor. The integral drum allows the use of a
drum-and-shoe type parking brake system. All other components are similar to their front disc brake
components.
Brake Pads
REMOVAL & INSTALLATION
Exploded view of the rear disc brake assemblyClick to enlarge
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.
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.
1. 
Loosen the wheel lug nuts then raise and safely support the rear of the vehicle.
2. 
Remove the wheel.
3. 
Place an 8 in. (203mm) C-clamp on the caliper and tighten the clamp to bottom the caliper pistons in
their bores. Remove the clamp.
4. 
Remove the two caliper slide pin bolts.
5. 
REAR DISC BRAKES 1039 
						

							
Use care to retain as much of the original caliper slide pin grease as possible.
Work the rear brake caliper off of the brake pads and adapter mount.
6. 
Position the caliper on a frame member or suspend it with some wire. Do not allow the caliper to hang
by the brake hose.
7. 
Remove and discard the pad slippers.
8. 
Remove the outboard brake pad by pressing it in enough to release the locating lug at one end then
swing it up to release the other end.
9. 
Remove the inboard brake pad by tilting it enough to release the retainer spring from the caliper
piston.
10. 
To install: Inspect the rear brake caliper for damage and wear. Replace as necessary.
11. 
Position the inboard brake pad in the caliper and press the retainer spring fully into the caliper piston.
12. 
Start one end of the outboard pad on the brake caliper and rotate it down until the locating lugs and
the retainer spring are fully seated.
13. 
Install new shoe slippers to the caliper mount.
14. 
View of the caliper installed to the disc brake adapter
Position the brake caliper over the rotor and align the sliding pin mounts.
15. 
Install the caliper bolts and tighten them to 20 ft. lbs. (27 Nm).
16. 
Install the wheel and snug the lug nuts.
17. 
Lower the vehicle and tighten the lug nuts to 100 ft. lbs. (135 Nm).
18. 
Check the brake fluid level in the master cylinder reservoir and correct as necessary.
19. 
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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1040 REMOVAL & INSTALLATION