1991 1999 ford explorer chilton User Manual

							View of the 1991-94 front disc brake components
Click to enlarge
Ford used two types of calipers on the Ranger, Explorer and Mountaineer trucks; A single piston caliper was
used from 1991-94 and a dual piston caliper was used on 1995-99 models. The single piston caliper is
retained by two push pins, which also act as the calipers sliding surface. The outboard pad mounts directly to
the single piston caliper. The dual piston caliper is mounted to an anchor plate by two slider bolts. The pads
are mounted to the anchor plate rather than the caliper.
Brake Pads
INSPECTION
Replace the front pads when the pad thickness is at the minimum thickness recommended by the Ford Motor
Co. which is  1
/32  in. (0.1mm), or at the minimum allowed by the applicable state or local motor vehicle
inspection code. Pad thickness may be checked by removing the wheel and looking through the inspection
port in the caliper assembly.
REMOVAL & INSTALLATION
Single Piston Caliper CAUTION
Always replace all disc pad assemblies on an axle. Never service one wheel only.
Ford recommends that new caliper pins be installed whenever the caliper is removed from the steering
knuckle.
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
990 Introduction 
						

							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.
2. 
Raise the vehicle and install jackstands. Remove a front wheel and tire assembly.
3. 
Place an 1 in. (133mm) C-clamp on the caliper and tighten the clamp slightly to push the caliper
piston in its bore. This will ease caliper removal from the rotor. Remove the clamp.
4. 
Do not use a screwdriver or similar tool to pry piston away from the rotor. There are 3 types of caliper pins used: a single tang type, a double tang type and a split-shell type.
The pin removal process is dependent upon how the pin is installed (bolt head direction). Remove the
upper caliper pin first.
5. 
On some applications, the pin may be retained by a nut and Torx® head bolt (except the split-shell
type).
If the bolt head is on the outside of the caliper, use the following procedure:From the inner side of the caliper, tap the bolt within the caliper pin until the bolt head on the
outer side of the caliper shows a separation between the bolt head and the caliper pin.
1. 
Using a hacksaw or bolt cutter, remove the bolt head from the bolt.
2. 
Depress the tab on the bolt head end of the upper caliper pin with a screwdriver, while
tapping on the pin with a hammer. Continue tapping until the tab is depressed by the V-slot.
3. 
Place one end of a punch,  1
/2  in. (6mm) or smaller, against the end of the caliper pin and drive
the caliper pin out of the caliper toward the inside of the vehicle. Do not use a screwdriver or
other edged tool to help drive out the caliper pin as the V-grooves may be damage.
4. 
6. 
WARNING
Never reuse caliper pins. Always install new pins whenever a caliper is removed.
If the nut end of the bolt is on the outside of the caliper, use the following procedure: Remove the nut from the bolt.
1. 
Depress the lead tang on the end of the upper caliper pin with a screwdriver while tapping on
the pin with a hammer. Continue tapping until the lead tang is depressed by the V-slot.
2. 
Place one end of a punch,  1
/2  in. (6mm) or smaller, against the end of the caliper pin and drive
the caliper pin out of the caliper toward the inside of the vehicle. Do not use a screwdriver or
other edged tool to help drive out the caliper pin as the V-grooves may be damaged.
3. 
7. 
Repeat the procedure in Step 4 for the lower caliper pin.
8.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 991 
						

							Before beginning the brake pad procedure, remove some fluid from the master cylinder
Two styles of caliper pins used, single tang pin is similar to the double tang Click to enlarge
View of a caliper pin with the bolt head facing the outside of the caliper HOW TO USE THIS BOOK
992 REMOVAL & INSTALLATION 
						

							Use a hacksaw to remove the bolt head from the pin
View of a caliper pin with the nut facing the outside of the caliper Click to enlarge
HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 993 
						

							Use a hammer and punch, and drive the caliper pin out from between the caliper and its mount
When removing the pin, you may need to depress the pin tab with a tool Click to enlarge
HOW TO USE THIS BOOK
994 REMOVAL & INSTALLATION 
						

							Pull the out from behind the caliper. Repeat the procedure for the lower pin
Remove the caliper from the rotor.
9. 
Remove the outer pad. Remove the anti-rattle clips and remove the inner pad.
10. 
Place the inner pads friction material against the caliper piston and assemble the C-clamp to the
caliper again. Tighten the clamp until the caliper piston is fully seated into its bore.
11. 
Slide the caliper assembly off of the rotorHOW TO USE THIS BOOK
REMOVAL & INSTALLATION 995 
						

							Holding the caliper as shown, press down then slide the pad out to remove it from the caliper
Click to enlarge
Remove the outer brake pad from the caliper HOW TO USE THIS BOOK
996 REMOVAL & INSTALLATION 
						

							If necessary, support the caliper by a length of wire from the frame. Never let it hang by the hose
Finally, remove the inner brake pad from the steering knuckle assembly HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 997 
						

							Place the inner pads friction material against the caliper piston and press it in with a C-clamp
Ensure that the anti-rattle clip is installed as shown on the inner pad HOW TO USE THIS BOOK
998 REMOVAL & INSTALLATION 
						

							View of a correctly installed outer pad
Click to enlarge
Install the upper caliper pin with the tang facing up-tangs are installed facing down on the bottom pin
Click to enlarge
HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 999