Replacement
Removal1. Raise vehicle on hoist.
2. Remove wheel and tire assembly from rotor mounting face. Do not damage wheel cylinder bleeder screw fitting during removal.
3. Disconnect front brake hose from front disc brake caliper. Remove hollow retaining bolt that connects hose fitting to front disc brake caliper. Remove hose assembly from front disc brake caliper and plug hose. Discard copper washers.
4. Remove two rear brake pin retainers.
5. Lift disc brake caliper off front disc brake rotor using rotating motion.
Installation
NOTE: If front disc brake rotor has been moved relative to the wheel hub and rust or dirt may have shifted between front disc brake rotor and wheel hub, on-vehicle rotor runout can be increased significantly. This can lead to brake shudder. Clean all dirt or foreign material from mating surfaces of caliper locating pins and caliper housing ears. Dirt can cause caliper locating pins to be crooked after rear brake pin retainers are torqued, preventing disc brake caliper from sliding properly.
1. CAUTION: Do not pry directly against metal piston, or damage to piston will occur.
Retract caliper piston fully in caliper piston bore. Make sure inner and outer shoes are properly positioned in front disc brake caliper anchor plate. Make sure front wheel disc brake shoe insulators are attached to the brake shoe plate. Make sure lining material is facing front disc brake rotor. Position disc brake caliper over front disc brake rotor and brake shoes and linings.
2. Install rear brake pin retainer through front disc brake caliper holes into disc brake caliper locating pins and hand start.
Make sure the correct disc brake caliper is installed on correct side of vehicle. The bleeder screw should be positioned on top of disc brake caliper when assembled on vehicle.
3. Tighten two rear brake pin retainers to 31 - 38 Nm (23 - 28 ft. lbs.).
4. Remove plug and install front brake hose on disc brake caliper with new copper washer on each side of fitting outlet. Insert retaining bolt through washers and fitting. Tighten to 41 - 54 Nm (31 - 39 ft. lbs.).
5. NOTE: Always replace rubber bleed screw cap after bleeding.
Bleed the serviced disc brake caliper.
6. Fill brake master cylinder reservoir with specified brake fluid to MAX line to 4 mm (0.16 inch) below on reservoir. Use High Performance DOT-3 Motor Vehicle Brake Fluid C6AZ-19542-AB or DOT-3 equivalent meeting Ford specification ESA-M6C25-A. If DOT 3 is not available use DOT 4 Brake Fluid meeting Ford specification SAE-J-1704-DOT 4.
7. 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.
Install wheel and tire assembly on vehicle. Tighten lug nuts to 115 - 142 Nm (85 - 104 ft. lbs.) using Rotunda Accutorq Lug Nut Socket 164-R0303 or equivalent on a 1/2 inch air impact wrench, or use a torque wrench.
8. Lower vehicle.
9. Road test vehicle.