1991 1999 ford explorer chilton User Manual

							Ensure that the tang is driven flush to the caliper mount
Click to enlarge
After installing the pins, ensure that the tangs are free to contact either side of the caliper mount Click to enlarge
To install: Place a new anti-rattle clip on the lower end of the inner pad. Be sure the tabs on the clip are
positioned properly and the clip is fully seated.
1.  HOW TO USE THIS BOOK
1000 REMOVAL & INSTALLATION 
						

							Position the inner pads and anti-rattle clip in the abutment with the anti-rattle clip tab against the pad
abutment and the loop-type spring away from the rotor. Compress the anti-rattle clip and slide the
upper end of the pad in position.
2. 
Install the outer pad, making sure the torque buttons on the pad spring clip are seated solidly in the
matching holes in the caliper.
3. 
Install the caliper on the spindle, making sure the mounting surfaces are free of dirt and lubricate the
caliper grooves with Disc Brake Caliper Grease. Install new caliper pins, making sure the pins are
installed with the tang in position as shown. The pin must be installed with the lead tang in first, the
bolt head facing outward (if equipped) and the pin positioned as shown. Position the lead tang in the
V-slot mounting surface and drive in the caliper until the drive tang is flush with the caliper
assembly. Install the nut (if equipped) and tighten to 32-47 inch lbs.
4. 
WARNING
Never reuse caliper pins. Always install new pins whenever a caliper is removed.
Install the wheel and tire assembly.
5. 
Remove the jackstands and lower the vehicle. Torque the lug nuts to 30 ft. lbs. (65 Nm).
6. 
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.
Check the brake fluid level and fill as necessary. Check the brakes for proper operation before driving
the vehicle.
7. 
Dual Piston Caliper HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 1001 
						

							Exploded view of the 4x4 Ranger front brake caliper assembly-4x2 Ranger similar
Click to enlarge
HOW TO USE THIS BOOK
1002 REMOVAL & INSTALLATION 
						

							Exploded view of the 4x4 Explorer/Mountaineer front brake caliper assembly-4x2 models
similar
Click to enlarge
HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 1003 
						

							Use a C-clamp to slightly press in the caliper piston to aid removal
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.
2. 
Raise and safely support the front of the vehicle. Remove the wheel.
3. 
Place an 1 in. (133mm) 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 and lift the caliper from the anchor plate.
5. 
Use care to retain as much of the original caliper slide pin grease as possible. Position the caliper on a frame member or suspend it with some wire. Do not allow the caliper to hang
by the brake hose.
6. 
Remove the brake pads and, if necessary, the anti-rattle clips from the anchor plate.
7. 
Remove the shims, if any, from the brake pads for re-use.
8. 
To install: If removed, install the anti-rattle clips.
2. 
Install the brake pads to the anchor plate.
3. 
Position the caliper over the brake pads and align the slide pin mounting holes.
4. 
Install the slide pin bolts and tighten them to 14-26 ft. lbs. (30-36 Nm).
5. 
Install the wheel and snug the lug nuts.
6. 
Lower the vehicle and tighten the lug nuts to 30 ft. lbs. (65 Nm).
7.  HOW TO USE THIS BOOK
1004 REMOVAL & INSTALLATION 
						

							
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.
8. 
Calipers
Exploded view of the single piston caliperClick to enlarge
HOW TO USE THIS BOOK
Calipers 1005 
						

							Cross-sectional view of the dual piston caliper
Click to enlarge
REMOVAL & INSTALLATION Follow the procedures for pad removal earlier in this section.
1.  HOW TO USE THIS BOOK
1006 REMOVAL & INSTALLATION 
						

							Loosen the brake hose-to-caliper retaining bolt ...
Remove the brake hose-to-caliper attaching bolt.
2. 
... then remove it, along with the hose fitting and the sealing washers
Always discard the old sealing washers and use new ones when installing the caliper
Discard the brass washers and plug the brake hose and caliper bolt hole.
3.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 1007 
						

							On dual piston caliper models, and if necessary, remove the brake pad anchor plate by removing the
two attaching screws from the back of the steering knuckle.
4. 
Inspect the caliper, piston and rubber seals/boots for damage and replace as necessary.
5. 
To install: On dual piston calipers, and if removed, position the anchor plat to the steering knuckle and install the
two retaining bolts. Use a threadlocking compound on the old bolts or install new bolts and tighten
them to 73-97 ft. lbs. (98-132 Nm).
6. 
If it was necessary to remove the brake pads, install them to the anchor plate (dual piston) or caliper
(single piston).
7. 
Install the caliper as instructed in the brake pad installation procedures.
8. 
Always use new sealing washers when assembling the hose to the brake caliper. Place a new sealing washer on the brake hose bolt, slide the bolt through the hose fitting and install a
second sealing washer to the bolt.
9. 
Position the hose/bolt to the caliper then tighten the bolt to 1-29 ft. lbs. (30-40 Nm).
10. 
Bleed the brake system. Check for leaks and proper operation before placing the vehicle into service.
11. 
OVERHAUL
Some vehicles may be equipped dual piston calipers. The procedure to overhaul the caliper is
essentially the same with the exception of multiple pistons, O-rings and dust boots.
Remove the caliper from the vehicle and place on a clean workbench.
1. 
CAUTION
NEVER place your fingers in front of the pistons in an attempt to catch or protect the pistons when applying
compressed air. This could result in personal injury!
Depending upon the vehicle, there are two different ways to remove the piston from the caliper. Refer
to the brake pad replacement procedure to make sure you have the correct procedure for your vehicle.
The first method is as follows:Stuff a shop towel or a block of wood into the caliper to catch the piston.
1. 
Remove the caliper piston using compressed air applied into the caliper inlet hole. Inspect the
piston for scoring, nicks, corrosion and/or worn or damaged chrome plating. The piston must
be replaced if any of these conditions are found.
2. 
2.  HOW TO USE THIS BOOK
1008 OVERHAUL 
						

							For some types of calipers, use compressed air to drive the piston out of the caliper, but make
sure to keep your fingers clear
Withdraw the piston from the caliper bore
For the second method, you must rotate the piston to retract it from the caliper.
3. 
If equipped, remove the anti-rattle clip.
4. 
Use a prytool to remove the caliper boot, being careful not to scratch the housing bore.
5.  HOW TO USE THIS BOOK
OVERHAUL 1009