Front

Pads

Removal

1. 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.

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





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

Inspect the pads for wear and contamination.





5. CAUTION: Do not ply in caliper piglet hole to retract pistons as this can damage the pistons and boots.

CAUTION: When removing the disc brake caliper, never allow it to hang from the brake hose.

Provide a suitable support. Remove the disc brake caliper.
1 Remove two front disc brake caliper bolts.
2 Lift the disc brake caliper off the Font disc brake caliper anchor plate.





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





7. Measure the brake disc thickness.
^ Install a new brake disc 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 disc brake caliper anchor plate stainless steel slippers and discard.





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

Install the pads.
1 Install the new disc brake caliper anchor plate stainless steel slippers. If required, make sure the slippers are clean and in good condition.
2 Install the pads.





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

Compress the caliper pistons.





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

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





NOTE: Tighten the lower caliper bolt first.

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

5. Install the wheel and tire assembly.
6. Lower the vehicle.
7. Fill the brake master cylinder reservoir with clean High Performance DOT 3 Motor Vehicle Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A. If DOT 3 is not available, use DOT 4 Brake Fluid meeting Ford specification SAE-J1704-DOT4. Install brake master cylinder filler cap.

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

Inspect brake operation.