1996 Aerostar Disk Brake System Brake Caliper Service And Repair - Inspection

1996 Ford Truck Aerostar AWD V6-245 4.0L

Copyright © 2008, ALLDATA

9.90

Page 1

Brake Caliper: Service and Repair Inspection INSTALLATION 1. The wheel cylinder piston must be "bottomed out" when installing new shoe and lining assemblies. Be sure that enough fluid has been removed from brake master cylinder (see Step 1 of Removal) to prevent fluid overflow. Bottom out the wheel cylinder piston with an eight-inch C-clamp using a worn-out inner shoe or a block of wood to push against the wheel cylinder piston. 2. Place a new brake shoe hold down spring on the lower end of the inner shoe. Be sure the tabs on the front disc brake caliper are positioned properly and the front disc brake caliper is fully seated.

3. Position the inner shoe and front disc brake caliper in the shoe abutment of the front wheel spindle with the anti-rattle clip tab against the shoe abutment and the loop-type spring away from the front disc brake rotor. 4. Compress the front disc brake caliper and slide the upper end of the shoe in position.

WARNING: Outer shoe torque buttons must be solidly seated in caliper holes or temporary loss of brakes may occur. 5. Install the outer shoe, making sure the torque buttons on the shoe are seated solidly in the matching holes in the front disc brake caliper. 6. Make sure the mounting surfaces are free of dirt and corrosion, and lubricate the caliper grooves with Disc Brake Caliper Grease D7AZ-19590-A (ESA-M1C172-A) or equivalent, then position the front disc brake caliper on the front wheel spindle. NOTE: Be sure to install the caliper pins so the retention tabs will be in contact with the front wheel spindle, not the front disc brake caliper. When the upper pin is properly positioned, the retention tabs will be at the top, against the front wheel spindle. When the lower pin is properly positioned, the retention tabs will be at the bottom, also in contact with the front wheel spindle.

1996 Ford Truck Aerostar AWD V6-245 4.0L

Copyright © 2008, ALLDATA

9.90

Page 2

Caliper Slide Pin Positioning 7. From the caliper outboard side, position the pin between the front disc brake caliper and spindle grooves. The pin must be positioned so the tabs will be installed against the spindle outer face. NOTE: During the installation procedure, do not allow the tabs of the caliper pin to be tapped too far into the spindle groove. If this happens, it will be necessary to tap the other end of the caliper pin until the tabs snap into place. The tabs on each end of the caliper pin must be free to catch on the spindle face.

Caliper Pin Installation 8. Tap the pin on the outboard end with a hammer. Continue tapping the pin inward until the retention tabs on the sides of the pin contact the front wheel spindle face. Repeat procedure for the lower pin. 9. If removed, install the front brake hose to the front disc brake caliper. 10. If the front brake hose was removed, perform brake bleeding procedures. 11. Install the wheel and tire assembly. Tighten lugnuts to 114-141 Nm (85-105 ft lb). 12. Lower vehicle, check the brake fluid level and fill as necessary. Check brakes for proper operation then recheck brake fluid level in brake master cylinder. Fill as necessary.