Thunderbird V8-4.6L VIN W (1997)
Brake Caliper: Service and Repair
Removal and Installation
With 15 Inch Wheels
REMOVAL
1. Raise and support vehicle.
2. Remove front wheel and tire assembly. Use care to avoid damage to or interference with brake caliper bleeder screw during removal.
3. Mark disc brake caliper assembly to make sure it will be reinstalled on correct side during installation.
4. Remove hollow bolt that retains brake hose to disc brake caliper. Remove brake hose from disc brake caliper and plug hose. It is not necessary to
remove the brake hose from the disc brake caliper if the brake shoe and lining or disc brake rotor is to be serviced.
5. Remove the one brake caliper bolt.
6. Rotate disc brake caliper approximately 90 degrees away from disc brake caliper anchor plate.
7. Slide disc brake caliper away from disc brake caliper anchor plate until caliper disengages from upper disc brake caliper locating pin.
INSTALLATION
1. Install replacement disc brake caliper by engaging upper brake caliper bolt into insulator.
2. Rotate disc brake caliper in place on disc brake caliper anchor plate.
3. Lubricate disc brake caliper locating pin with silicone brake caliper grease and dielectric compound. Install a new brake caliper bolt and tighten to
81 Nm (60 ft. lbs.).
4. Remove plug and install brake hose on disc brake caliper with new copper washers on each side of fitting outlet. Insert new retaining bolt through
washers and fitting. Tighten bolt to 40-60 Nm (30-44 ft. lbs.).
5. Bleed disc brake caliper that was serviced. Always reinstall rubber bleeder screw cap after bleeding.
6. Fill brake master cylinder with DOT-3 motor vehicle brake fluid.
CAUTION: Failure to tighten lug nuts in a star pattern may result in high rotor runout, which will speed up the development of brake roughness,
shudder and vibration.
7. Install wheel and tire assembly using Accutorq(r) lug nut sockets or equivalent on 1/2 inch drive air impact wrench or use torque wrench to tighten
lug nuts to 115-142 Nm (85-104 ft. lbs.).
8. Lower vehicle.
9. Pump brake pedal prior to moving vehicle to position brake shoes and linings. Refill the brake master cylinder with DOT-3 motor vehicle brake
fluid.
10. Road test vehicle.
With 16 Inch Wheels
REMOVAL
1. Raise and support vehicle.
2. Remove front wheel and tire assembly. Use care to avoid damage to or interference with wheel cylinder bleeder screw during removal.
3. Mark disc brake caliper assembly to make sure it will be reinstalled on correct side during installation.
4. Remove hollow bolt that retains brake hose to disc brake caliper. Remove brake hose from disc brake caliper and plug hose. It is not necessary to
remove the brake hose from the disc brake caliper if the brake shoe and lining or disc brake rotor is to be serviced.
5. Remove the two brake pin retainers.
6. Rotate disc brake caliper until disc brake caliper is free from disc brake caliper anchor plate.
INSTALLATION
1. Check caliper locating pins for freedom of movement. If binding, lubricate disc brake caliper locating pin with Silicone Brake Caliper Grease and
Dielectric Compound.
2. Position disc brake caliper on disc brake caliper anchor plate.
3. Tighten upper and lower brake pin retainers to 35 Nm (26 ft. lbs.).
4. Remove plug and install brake hose on disc brake caliper with new copper washers on each side of fitting outlet. Insert new retaining bolt through
washers and fitting. Tighten bolt to 40-60 Nm (30-44 ft. lbs.).
5. Bleed disc brake caliper that was serviced. Always reinstall rubber bleeder screw cap after bleeding.
6. Fill brake master cylinder with DOT-3 motor vehicle brake fluid.
CAUTION: Failure to tighten lug nuts in a star pattern may result in high rotor runout, which will speed up the development of brake roughness,
shudder and vibration.
7. Install wheel and tire assembly using Accutorq(r) lug nut sockets or equivalent on 1/2 inch drive air impact wrench or use torque wrench to tighten
lug nuts to 115-142 Nm (85-104 ft. lbs.).
8. Lower vehicle.
9. Pump brake pedal prior to moving vehicle to position brake shoes and linings. Refill the brake master cylinder with DOT-3 motor vehicle brake
fluid.
10. Road test vehicle.
