Aerostar 2WD V6-245 4.0L (1990)
Brake Pad: Service and Repair
Removal and Installation
Pin Slider Caliper
A rattling noise may be heard in the front wheel area of some 1988 Aerostar, Bronco II, and Ranger vehicles when driven on rough roads. This may be
due to the caliper pins shifting, allowing the disc brake calipers to rattle. To correct this condition, install new design caliper pins (part No.
E8TZ-2C150-B).
REMOVAL
1.
Drain a small amount of brake fluid from master cylinder reservoir.
2.
Raise and support vehicle, then remove front wheel and tire assemblies.
3.
Place an eight inch C-clamp or equivalent on caliper and tighten clamp until piston(s) bottoms in cylinder bore(s), then remove clamp. Do not pry
piston(s) away from rotor.
4.
On 1987-88 Bronco II and Ranger models, proceed as follows:
a.
Clean dirt from area around pin tabs.
b.
Tap upper caliper pin towards inboard side until pin tabs touch spindle face.
c.
Insert a screwdriver into slot provided behind pin tabs on inboard side of pin.
d.
Compress outboard end of pin with needle nose pliers, while prying with screwdriver until tabs slip into spindle groove.
e.
Position one end of a 7/16 inch punch against end of the caliper pin and drive caliper pin out of caliper slide groove.
5.
On 1988-92 Aerostar and 1989-90 Bronco II, Explorer and Ranger models, proceed as follows:
a.
Clean dirt from area around pin tabs.
b.
Using a 1/4 X 3/8 inch deep socket, tap upper caliper pin towards outboard side until pin tabs pass spindle face.
c.
Compress inboard pin tab with a suitable pliers, then tap pin with a hammer until tab slips into the spindle groove.
d.
Position a 7/16 inch punch against end of caliper pin and drive caliper pin out of caliper slide groove.
6.
On all models, remove caliper from rotor. Disconnect hydraulic line from caliper only if caliper service is required. If not being removed for
service, properly support caliper.
7.
Remove brake pads, anti-rattle clip and/or spring.
INSTALLATION
1.
Clean caliper mounting surfaces.
2.
Ensure caliper pistons are bottomed in cylinder bores.
3.
On single piston calipers, proceed as follows:
a.
Place new anti-rattle clip on lower end of inner shoe. Ensure tabs on clip are properly positioned and clip is fully seated.
b.
Place inner shoe and anti-rattle clip in shoe abutment with anti-rattle clip tab against shoe abutment and loop-type spring away from rotor.
Compress anti-rattle clip and slide upper end of shoe into position.
c.
Position outer brake pad on caliper and press pad tabs into place.
4.
On all calipers, apply suitable lubricant to caliper grooves, then install caliper on spindle. Position pin with pin retention tabs adjacent to spindle
groove. Tap pin on outboard end with a hammer until tabs contact spindle face.
5.
If removed, install brake hose to caliper.
6.
If hydraulic system was opened during repair procedure, bleed the brakes as outlined in BRAKE BLEEDING.
7.
Install wheel and tire assemblies.
8.
Lower vehicle, check brake fluid level and replenish as necessary, then check brakes for proper operation.
Rail Slider Caliper
REMOVAL
1.
Drain a small amount of brake fluid from master cylinder reservoir.
2.
Raise and support vehicle, then remove wheel and tire assembly.
3.
Install an eight inch C-clamp on caliper housing and tighten clamp to bottom piston(s) in cylinder bore(s), then remove clamp. Do not use
screwdriver or other edged tool to pry piston(s) from rotor.
4.
Remove key retaining screw, then using a hammer and drift, drive out caliper support key and spring.
5.
On single piston calipers, push caliper downward against spindle, then rotate upper end upward and out of spindle assembly.
6.
On dual piston calipers, rotate key and spring end of caliper out and away from rotor, then slide opposite end of caliper clear of mount and off
the rotor.
7.
On all calipers, disconnect hydraulic line from caliper only if caliper service is required. If not being removed for service, properly support
caliper.
8.
On single piston calipers, remove outer brake pad by tapping to loosen pad flange, then the inner pad and the anti-rattle clip.
9.
On dual piston calipers, remove anti-rattle spring and brake pads.
INSTALLATION
1.
On single piston calipers, proceed as follows:
