(A) - Front Disc Brake "Knocking" Noise When Braking Gently

ISSUE:

A "knocking" noise proportional to wheel rotation may be heard from the front brakes during gentle braking. If pressure is maintained on the brake pedal when the noise occurs, the noise will continue until the vehicle comes to a complete stop. This noise may be due to wear spots and ridges on the upper main caliper sleeve. This condition does not affect brake performance or stopping distance.

ACTION:
Replace the old caliper sleeve with a revised caliper sleeve. The new improved part is made of a harder material which is more resistant to wear spots and ridge formation. Refer to the following procedure and to the appropriate year Escort/Tracer Service Manual, Section 06-03. for service details.

NOTE:
THE "KNOCKING" NOISE REFERENCED IN THIS TSB ARTICLE IS COMPLETELY DIFFERENT FROM THE "SQUEALING" OR "SQUEAKING" NOISE CAUSED BY BRAKE PADS.

1. Raise and support the vehicle. Refer to the appropriate year Escort/Tracer Service Manual, Section 00-02.

2. Remove the two (2) brake caliper bolts and remove the brake caliper from the knuckle/rotor. Secure the brake caliper with mechanic's wire to prevent damage to the brake hoses.





3. Remove the upper main caliper sleeve and boots, Figure 1. Refer to the appropriate year Escort/Tracer Service Manual, Section 06-03, for removal procedure.

NOTE:
IT IS NOT NECESSARY TO REPLACE THE LOWER CALIPER SLEEVES OR ANY OF THE RUBBER DUST BOOTS UNLESS WORN OR DAMAGED.

4. Install new upper main caliper sleeves and reinstall dust boots. Reverse the removal procedure to install. Torque the caliper sleeve bolts to 49-63 N.m (3646 lb-ft).

PART NUMBER PART NAME

F4CZ-2B393-A Caliper Sleeve