1991 1999 ford explorer chilton User Manual

Booster pushrod gauge adjustment procedure
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Cutaway view of the vacuum assisted power brake booster assembly Click to enlarge
HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 979 

Booster mounting
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HOW TO USE THIS BOOK
980 REMOVAL & INSTALLATION 

Booster vacuum hose connections for the 2.3L & 2.9L engines£.0L engine similar to 2.9L
engine
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HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 981 

Booster vacuum hose connections for the 3.0L-4.0L engine similar
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Disconnect the stop lamp switch wiring to prevent running the battery down.
1. 
Support the master cylinder from the underside with a prop.
2. 
Remove the master cylinder-to-booster retaining nuts.
3. 
Loosen the clamp that secures the manifold vacuum hose to the booster check valve, and remove the
hose. Remove the booster check valve.
4. 
Pull the master cylinder off the booster and leave it supported by the prop, far...

Start the engine and check brake operation.
14. 
Brake Hoses and Lines
Metal lines and rubber brake hoses should be checked frequently for leaks and external damage. Metal lines
are particularly prone to crushing and kinking under the vehicle. Any such deformation can restrict the proper
flow of fluid and therefore impair braking at the wheels. Rubber hoses should be checked for cracking or
scraping; such damage can create a weak spot in the hose and it could fail under pressure.
Any time the lines are...

Use two wrenches to loosen the fitting. If available, use flare nut type wrenches
Disconnect the other end of the line or hose, moving the drain pan if necessary. Always use a
back-up wrench to avoid damaging the fitting.
7. 
Disconnect any retaining clips or brackets holding the line and remove the line from the vehicle.
8. 
If the brake system is to remain open for more time than it takes to swap lines, tape or plug each
remaining clip and port to keep contaminants out and fluid in.
Any gaskets/crush...

Tape or plug the line to prevent contamination
To install:
Install the new line or hose, starting with the end farthest from the master cylinder. Connect the other
end, then confirm that both fittings are correctly threaded and turn smoothly using finger pressure.
Make sure the new line will not rub against any other part. Brake lines must be at least 1/2 in. (13mm)
from the steering column and other moving parts. Any protective shielding or insulators must be
reinstalled in the original location.
9....

system, no matter how clean it is.
It will be necessary to centralize the pressure differential value after a brake system failure has been corrected
and the hydraulic system has been bled.
The primary and secondary hydraulic brake systems are individual systems and are bled separately. During
the entire bleeding operation, do not allow the reservoir to run dry. Keep the master cylinder reservoir filled
with brake fluid.
Clean all dirt from around the master cylinder fill cap, remove the cap and fill...

Bleed the caliper until you can see clean, air bubble free brake fluid moving through the tube
Open the bleeder screw valve  1
/2 - 3
/4  turn.
4. 
Have an assistant slowly depress the brake pedal. Close the bleeder screw valve and tell your assistant
to allow the brake pedal to return slowly. Continue this pumping action to force any air out of the
system. When bubbles cease to appear at the end of the bleeder hose, close the bleeder valve and
remove the hose.
5. 
Check the master cylinder fluid level...

FRONT DISC BRAKES
Introduction
Exploded view of the 1991-94 front disc brake assembly-4-wheel ABS sensor not shown Click to enlarge
FRONT DISC BRAKES 989