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

1996 Ford Truck Aerostar AWD V6-245 4.0L

Copyright © 2008, ALLDATA

9.90

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Brake Caliper: Service and Repair Removal NOTE: If the front disc brake calipers are to be removed for service other than to replace brake shoes, fluid removal from the brake master cylinder (2140) may not be required. Removing some fluid will prevent fluid from overflowing from the brake master cylinder when the wheel cylinder piston are pressed into their bores. CAUTION: System contamination may result if anything other than a clean device is used to remove fluid from brake master cylinder. REMOVAL 1. Use a clean siphon or suction hose to remove a portion of the fluid from the brake master cylinder. Discard the removed fluid. 2. Raise the vehicle and install safety stands. Remove a front wheel and tire assembly. CAUTIONS: ^ Do not position C-clamp on the brake shoe hold down spring. Also, do not compress wheel cylinder piston further than is required to disengage torque buttons from front disc brake caliper. Damage to the brake shoe hold down spring will result. Replace shoe if brake shoe hold down spring is bent or damaged. ^ Do not attempt to "bottom" the wheel cylinder piston in the bore at this time. Use an old, worn out brake shoe or block of wood and the C-clamp to bottom the wheel cylinder piston once the front disc brake caliper is removed from front disc brake rotor, and the shoes are removed from the front disc brake caliper.

3. Use an eight-inch C-clamp to move the wheel cylinder piston back into its bore as follows: a. Place the head of the C-clamp against the front disc brake caliper, and the screw end of the C-clamp against the outer shoe below the spring clip. b. Tighten the clamp until the torque buttons just clear the caliper (about 3mm [1/8 inch]). Remove the C-clamp. c. Do not use a screwdriver or similar tool to pry the wheel cylinder piston away from the front disc brake rotor. 4. Clean excess dirt from area around pin tabs. 5. Using Caliper Pin Remover D89T-2196-A or equivalent and a light hammer, drive the caliper pin from the front disc brake caliper as follows:

1996 Ford Truck Aerostar AWD V6-245 4.0L

Copyright © 2008, ALLDATA

9.90

Page 2

Caliper Pin Removal a. Position the notched end of the tool against the caliper pin (retention tab half), at a 45° angle from the pin retention tabs. b. Tap the tool with the hammer to compress the retention tabs. c. As the retention tabs are compressed, move the tool to gain a straight approach to the pin, and continue tapping to drive the pin through the caliper/spindle groove. 6. Remove the front disc brake caliper from the rotor. If the front disc brake caliper is to be removed for service, disconnect the brake hose from the front disc brake caliper. If not, secure the front disc brake caliper with wire. NOTE: do not let the front disc brake caliper hang with its weight on the front brake hose (2078).

Inner Brake Pad 7. Compress the brake shoe hold down spring and remove the inner shoe from the front disc brake caliper.

Outer Pad Removal 8. To remove the outer shoe from the front disc brake caliper, press each ear of the shoe away from the front disc brake caliper, slide the torque

1996 Ford Truck Aerostar AWD V6-245 4.0L

Copyright © 2008, ALLDATA

9.90

Page 3

buttons out of the retention notches and slide the shoe off. CAUTION: Never attempt to bottom out the wheel cylinder piston with the outer shoe installed.