1991 1999 ford explorer chilton User Manual

Use a prytool to carefully pry around the edge of the boot ...
... then remove the boot from the caliper housing, taking care not to score or damage the bore
Remove the piston seals from the groove in the caliper bore.
6.  HOW TO USE THIS BOOK
1010 OVERHAUL 

Use extreme caution when removing the piston seal; DO NOT scratch the caliper bore
Carefully loosen the brake bleeder valve cap and valve from the caliper housing.
7. 
Inspect the caliper bores, pistons and mounting threads for scoring or excessive wear.
8. 
Use crocus cloth to polish out light corrosion from the piston and bore.
9. 
Clean all parts with denatured alcohol and dry with compressed air.
10. 
To assemble: Lubricate and install the bleeder valve and cap.
11. 
Install the new seals into the...

Properly bleed the brake system.
18. 
Brake Rotor (Disc)
REMOVAL & INSTALLATION
Except 1995-99 4-Wheel Drive Models Loosen the wheel lug nuts.
1. 
Jack up the front of the vehicle and support on jackstands.
2. 
Remove the wheel and tire.
3. 
On 1991-94 models, remove the brake caliper assembly as described earlier in this Section, but do
not disconnect the brake hose.
4. 
On 1995-99 models, remove the two anchor plate-to-steering knuckle bolts then slide the assembly
off of the rotor.
5. 
Suspend the...

Disc brake service limits
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Inspect the rotor for cracks, grooves or waviness. Rotors that arent too badly scored or grooved can
be resurfaced by most automotive shops.
1. 
Measure the rotor thickness using a caliper gauge.
2. 
Minimum rotor thickness should be 0.81 in. (20.5mm). If refinishing exceeds that, the rotor will have
to be replaced.
3. 
Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. HOW TO USE THIS BOOK
INSPECTION 1013 

REAR DRUM BRAKES
Introduction
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REAR DRUM BRAKES 1015 

Component locations on the left side 10 in. brake assembly
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HOW TO USE THIS BOOK
1016 Introduction 

Component locations on the right side 10 in. brake assembly
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Brake Drums
REMOVAL & INSTALLATION CAUTION
Older brake pads or shoes may contain asbestos, which has been determined to be a cancer causing agent.
Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When
cleaning brake surfaces, use a commercially available brake cleaning fluid.
Raise the vehicle so that the wheel to be worked on is clear of the floor and install jackstands under...

To remove the rear brake drum, first safely raise the rear of the vehicle and remove the wheel ...
Remove the hub cap and the wheel/tire assembly. Remove the 3 retaining nuts and remove the brake
drum. It may be necessary to back off the brake shoe adjustment in order to remove the brake drum.
This is because the drum might be grooved or worn from being in service for an extended period of
time.
2. 
... then grasp hold of the drum and pull it from the axle flange and brake shoes
Before installing a new...

Drum brake service limits. The maximum inside diameter is cast into the drum
Click to enlarge
After the brake drum has been removed from the vehicle, it should be inspected for run-out, severe scoring
cracks, and the proper inside diameter.
Minor scores on a brake drum can be removed with fine emery cloth, provided that all grit is removed from
the drum before it is installed on the vehicle.
A badly scored, rough, or out-of-round (run-out) drum can be ground or turned on a brake drum lathe. Do
not remove...

Raise and support the vehicle and remove the wheel and brake drum from the wheel to be worked on.
1. 
If you have never replaced the brakes on a car before and you are not too familiar with the procedures
involved, only disassemble and assemble one side at a time, leaving the other side intact as a reference
during reassembly.
Install a clamp over the ends of the wheel cylinder to prevent the pistons of the wheel cylinder from
coming out, causing loss of fluid.
2. 
Contract the brake shoes by pulling the...