1991 1999 ford explorer chilton User Manual
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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 the anchor plate rather than the caliper. Brake Pads INSPECTION Replace the front pads when the pad thickness is at the minimum thickness recommended by the Ford Motor Co. which is 1 /32 in. (0.1mm), or at the minimum allowed by the applicable state or local motor vehicle inspection code. Pad thickness may be checked by removing the wheel and looking through the inspection port in the caliper assembly. REMOVAL & INSTALLATION Single Piston Caliper CAUTION Always replace all disc pad assemblies on an axle. Never service one wheel only. Ford recommends that new caliper pins be installed whenever the caliper is removed from the steering knuckle. 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. HOW TO USE THIS BOOK 990 Introduction
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 the rotor. Remove the clamp. 4. Do not use a screwdriver or similar tool to pry piston away from the rotor. There are 3 types of caliper pins used: a single tang type, a double tang type and a split-shell type. The pin removal process is dependent upon how the pin is installed (bolt head direction). Remove the upper caliper pin first. 5. On some applications, the pin may be retained by a nut and Torx® head bolt (except the split-shell type). If the bolt head is on the outside of the caliper, use the following procedure:From the inner side of the caliper, tap the bolt within the caliper pin until the bolt head on the outer side of the caliper shows a separation between the bolt head and the caliper pin. 1. Using a hacksaw or bolt cutter, remove the bolt head from the bolt. 2. Depress the tab on the bolt head end of the upper caliper pin with a screwdriver, while tapping on the pin with a hammer. Continue tapping until the tab is depressed by the V-slot. 3. Place one end of a punch, 1 /2 in. (6mm) or smaller, against the end of the caliper pin and drive the caliper pin out of the caliper toward the inside of the vehicle. Do not use a screwdriver or other edged tool to help drive out the caliper pin as the V-grooves may be damage. 4. 6. WARNING Never reuse caliper pins. Always install new pins whenever a caliper is removed. If the nut end of the bolt is on the outside of the caliper, use the following procedure: Remove the nut from the bolt. 1. Depress the lead tang on the end of the upper caliper pin with a screwdriver while tapping on the pin with a hammer. Continue tapping until the lead tang is depressed by the V-slot. 2. Place one end of a punch, 1 /2 in. (6mm) or smaller, against the end of the caliper pin and drive the caliper pin out of the caliper toward the inside of the vehicle. Do not use a screwdriver or other edged tool to help drive out the caliper pin as the V-grooves may be damaged. 3. 7. Repeat the procedure in Step 4 for the lower caliper pin. 8. HOW TO USE THIS BOOK REMOVAL & INSTALLATION 991
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 HOW TO USE THIS BOOK 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 HOW TO USE THIS BOOK REMOVAL & INSTALLATION 999