Front

REMOVAL

WARNING:
- ASBESTOS FIBER DUST MAY BE PRESENT ON BRAKE AND CLUTCH ASSEMBLIES AND IS HAZARDOUS TO HEALTH IF INHALED.
- BRAKE AND CLUTCH ASSEMBLIES SHOULD BE CLEANED USING A VACUUM CLEANER RECOMMENDED FOR USE WITH ASBESTOS FIBERS. THE BAG MUST BE LABELED PER OSHA INSTRUCTIONS, SEALED, AND THE TRASH HAULER NOTIFIED AS TO THE BAG'S CONTENTS.
- IF A VACUUM SUITABLE FOR ASBESTOS IS NOT AVAILABLE, CLEANING SHOULD BE DONE WET. IF DUST GENERATION IS STILL POSSIBLE, TECHNICIANS SHOULD WEAR GOVERNMENT-APPROVED TOXIC DUST PURIFYING RESPIRATORS.
- OCCUPATIONAL HEALTH AND SAFETY ACT (OSHA) REQUIRES AREAS WHERE ASBESTOS DUST GENERATION IS POSSIBLE TO BE ISOLATED AND POSTED WITH WARNING SIGNS. ONLY TECHNICIANS PERFORMING BRAKE OR CLUTCH REPAIR SHOULD BE PRESENT IN THE AREA.

1. Remove brake master cylinder filler cap. Check brake fluid level in brake master cylinder reservoir. Remove fluid until brake master cylinder reservoir is half full.

WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE LUGGAGE COMPARTMENT. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS.

2. Raise and support the vehicle.
3. Remove the wheel and tire assembly.





4. Inspect the pads for wear and contamination.

CAUTION: Replace the pad if worn to or past the specified thickness above the metal backing plate or rivets. Replace the pads in complete axle sets.





5. Remove the disc brake caliper.
1 Remove two front disc brake caliper bolts.
2 Lift the disc brake caliper off the front disc brake caliper anchor plate.

CAUTION:
- Do not pry in caliper sight hole to retract pistons as this can damage the pistons and boots.
- When removing the disc brake caliper, never allow it to hang from the brake hose. Provide a suitable support.





6. Remove the disc brake pad anti-rattle clip.





7. Measure the front disc brake rotor thickness.
- Replace the front disc brake rotor if not within specification.





8. Inspect the disc brake caliper.
- If leaks or damaged boots are found, disassembly is required.





9. Remove the pads and stainless steel slippers.
1 Remove the pads and verify thickness.
2 Remove the front disc brake caliper anchor plate stainless steel slippers and discard.





10. Inspect the front disc brake anchor plate assembly.
- Check the guide pin boots for damage.
- Check the guide pins for binding and damage.
- Replace worn or damaged pins.

INSTALLATION





1. Install the pads.
1 Install the new front disc brake caliper anchor plate stainless steel slippers.
2 Install the pads.

CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the pad lining material. Do not install contaminated pads.

NOTE: Replace all hardware supplied with pad kit.





2. Compress the caliper pistons.

NOTE: Use a wood block or used pad to protect pistons and boots.





3. Install the disc brake pad anti-rattle clip.





4. Install the disc brake caliper.
1 Install the disc brake caliper.
2 Install the disc brake caliper bolts.

CAUTION: Use care not to damage the bleeder screw or front disc brake rotor shield.

5. Install the wheel and tire assembly.
6. Lower the vehicle.
7. Fill the brake master cylinder reservoir with clean High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. Install brake master cylinder filler cap.
8. Inspect brake operation.

NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch.