1991 1999 ford explorer chilton User Manual

View of the 1991-94 front disc brake components
Click to enlarge
Ford used two types of calipers on the Ranger, Explorer and Mountaineer trucks; A single piston caliper was
used from 1991-94 and a dual piston caliper was used on 1995-99 models. The single piston caliper is
retained by two push pins, which also act as the calipers sliding surface. The outboard pad mounts directly to
the single piston caliper. The dual piston caliper is mounted to an anchor plate by two slider bolts. The pads
are mounted...

To avoid fluid overflow when the caliper piston is pressed into the caliper cylinder bores, remove or
siphon part of the brake fluid out of the master cylinder reservoir (connected to the front disc brakes).
Discard the removed fluid.
1. 
Loosen the wheel lug nuts.
2. 
Raise the vehicle and install jackstands. Remove a front wheel and tire assembly.
3. 
Place an 1 in. (133mm) C-clamp on the caliper and tighten the clamp slightly to push the caliper
piston in its bore. This will ease caliper removal from...

Before beginning the brake pad procedure, remove some fluid from the master cylinder
Two styles of caliper pins used, single tang pin is similar to the double tang Click to enlarge
View of a caliper pin with the bolt head facing the outside of the caliper HOW TO USE THIS BOOK
992 REMOVAL & INSTALLATION 

Use a hacksaw to remove the bolt head from the pin
View of a caliper pin with the nut facing the outside of the caliper Click to enlarge
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REMOVAL & INSTALLATION 993 

Use a hammer and punch, and drive the caliper pin out from between the caliper and its mount
When removing the pin, you may need to depress the pin tab with a tool Click to enlarge
HOW TO USE THIS BOOK
994 REMOVAL & INSTALLATION 

Pull the out from behind the caliper. Repeat the procedure for the lower pin
Remove the caliper from the rotor.
9. 
Remove the outer pad. Remove the anti-rattle clips and remove the inner pad.
10. 
Place the inner pads friction material against the caliper piston and assemble the C-clamp to the
caliper again. Tighten the clamp until the caliper piston is fully seated into its bore.
11. 
Slide the caliper assembly off of the rotorHOW TO USE THIS BOOK
REMOVAL & INSTALLATION 995 

Holding the caliper as shown, press down then slide the pad out to remove it from the caliper
Click to enlarge
Remove the outer brake pad from the caliper HOW TO USE THIS BOOK
996 REMOVAL & INSTALLATION 

If necessary, support the caliper by a length of wire from the frame. Never let it hang by the hose
Finally, remove the inner brake pad from the steering knuckle assembly HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 997 

Place the inner pads friction material against the caliper piston and press it in with a C-clamp
Ensure that the anti-rattle clip is installed as shown on the inner pad HOW TO USE THIS BOOK
998 REMOVAL & INSTALLATION 

View of a correctly installed outer pad
Click to enlarge
Install the upper caliper pin with the tang facing up-tangs are installed facing down on the bottom pin
Click to enlarge
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REMOVAL & INSTALLATION 999