1991 1999 ford explorer chilton User Manual

Ensure that the tang is driven flush to the caliper mount
Click to enlarge
After installing the pins, ensure that the tangs are free to contact either side of the caliper mount Click to enlarge
To install: Place a new anti-rattle clip on the lower end of the inner pad. Be sure the tabs on the clip are
positioned properly and the clip is fully seated.
1.  HOW TO USE THIS BOOK
1000 REMOVAL & INSTALLATION 

Position the inner pads and anti-rattle clip in the abutment with the anti-rattle clip tab against the pad
abutment and the loop-type spring away from the rotor. Compress the anti-rattle clip and slide the
upper end of the pad in position.
2. 
Install the outer pad, making sure the torque buttons on the pad spring clip are seated solidly in the
matching holes in the caliper.
3. 
Install the caliper on the spindle, making sure the mounting surfaces are free of dirt and lubricate the
caliper grooves with...

Exploded view of the 4x4 Ranger front brake caliper assembly-4x2 Ranger similar
Click to enlarge
HOW TO USE THIS BOOK
1002 REMOVAL & INSTALLATION 

Exploded view of the 4x4 Explorer/Mountaineer front brake caliper assembly-4x2 models
similar
Click to enlarge
HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 1003 

Use a C-clamp to slightly press in the caliper piston to aid removal
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.
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...

The first couple of times you apply the brakes, the pedal may go to the floor. Continue to pump the
brake pedal until it feels firm.
Start the engine and apply the brakes several times to readjust the caliper pistons. Ensure that the
pedal feels firm before operating the vehicle.
8. 
Calipers
Exploded view of the single piston caliperClick to enlarge
HOW TO USE THIS BOOK
Calipers 1005 

Cross-sectional view of the dual piston caliper
Click to enlarge
REMOVAL & INSTALLATION Follow the procedures for pad removal earlier in this section.
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1006 REMOVAL & INSTALLATION 

Loosen the brake hose-to-caliper retaining bolt ...
Remove the brake hose-to-caliper attaching bolt.
2. 
... then remove it, along with the hose fitting and the sealing washers
Always discard the old sealing washers and use new ones when installing the caliper
Discard the brass washers and plug the brake hose and caliper bolt hole.
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REMOVAL & INSTALLATION 1007 

On dual piston caliper models, and if necessary, remove the brake pad anchor plate by removing the
two attaching screws from the back of the steering knuckle.
4. 
Inspect the caliper, piston and rubber seals/boots for damage and replace as necessary.
5. 
To install: On dual piston calipers, and if removed, position the anchor plat to the steering knuckle and install the
two retaining bolts. Use a threadlocking compound on the old bolts or install new bolts and tighten
them to 73-97 ft. lbs. (98-132 Nm)....

For some types of calipers, use compressed air to drive the piston out of the caliper, but make
sure to keep your fingers clear
Withdraw the piston from the caliper bore
For the second method, you must rotate the piston to retract it from the caliper.
3. 
If equipped, remove the anti-rattle clip.
4. 
Use a prytool to remove the caliper boot, being careful not to scratch the housing bore.
5.  HOW TO USE THIS BOOK
OVERHAUL 1009