1996 Aerostar Disk Brake System Tsb's

1996 Ford Truck Aerostar AWD V6-245 4.0L

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Disc Brake System: Technical Service Bulletins Technical Service Bulletin # NHTSA98E010000

Date: 980407

Recall 98E010000: Brake Rotor Cracking Year: 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997 Make: FORD TRUCK Model: AEROSTAR Year: 1994 Make: MAZDA TRUCK Model: PICKUP Year: 1990 Make: FORD TRUCK Model: BRONCO II Year: 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994 Make: FORD TRUCK Model: RANGER Year of Recall: '98 Type of Report: Equipment Potential Number of Units Affected: 23500 Summary: Equipment Description: Brake rotors for use on Ford and Mazda trucks. Cracked castings caused cracks to appear on the outer diameter of the rotor hat or around the stud hole. Loss of braking can result. Aimco will reimburse consumers/installers for the cost of replacement rotors and installation. Consumers are requested to return to the location where the rotors were originally purchased/installed for replacement. Owner notification is expected to begin during April 1998. Owners who do not receive the free rotors within a reasonable time should contact Aimco at 1-800-264-3414. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).

Technical Service Bulletin # 98-5A-11

Brakes - Elimination Of Sanding Rotors And Drums Article No. 98-5A-11 03/18/98 BRAKES - ELIMINATION OF SANDING ROTORS AND DRUMS - SERVICE TIP FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1993-94 TOPAZ 1993-97 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER 1995-97 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 AEROSTAR, ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER, VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER

Date: 980318

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ISSUE: Repeat brake repairs have been performed due to sanding of brake rotors and drums. The sanding of rotors and drums may have been done in reference to a Service Manual or TSB article which prescribes sanding as a repair, however, sanding is neither an effective nor lasting repair for customer complaints of brake roughness or noise. ACTION: Machine brake rotors and drums instead of sanding to help reduce brake roughness caused by one of the following conditions: ^

Rotor thickness variation and lateral runout

^

Lining or foreign material build-up

^

Drum out-of-round

NOTE: DO NOT MACHINE OR SAND ROTORS/DRUMS TO REDUCE OCCASIONAL BRAKE NOISE. IT IS NEITHER AN EFFECTIVE OR LASTING REPAIR.

OTHER APPLICABLE ARTICLES: NONE

SUPERSEDES: 96-22-2

WARRANTY STATUS: INFORMATION ONLY

OASIS CODES: 301000 Technical Service Bulletin # NHTSA98E010000

Date: 980407

Recall 98E010000: Brake Rotor Cracking Year: 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997 Make: FORD TRUCK Model: AEROSTAR Year: 1994 Make: MAZDA TRUCK Model: PICKUP Year: 1990 Make: FORD TRUCK Model: BRONCO II Year: 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994 Make: FORD TRUCK Model: RANGER Year of Recall: '98 Type of Report: Equipment Potential Number of Units Affected: 23500 Summary: Equipment Description: Brake rotors for use on Ford and Mazda trucks. Cracked castings caused cracks to appear on the outer diameter of the rotor hat or around the stud hole. Loss of braking can result. Aimco will reimburse consumers/installers for the cost of replacement rotors and installation. Consumers are requested to return to the location where the rotors were originally purchased/installed for replacement. Owner notification is expected to begin during April 1998. Owners who do not receive the free rotors within a reasonable time should contact Aimco at 1-800-264-3414. Also contact the National Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).

Technical Service Bulletin # 99-19-4

Brakes - Vibration/Inspection Service Tips Article No. 99-19-4

Date: 990920

1996 Ford Truck Aerostar AWD V6-245 4.0L

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09/20/99 BRAKES - GUIDELINES FOR BRAKE VIBRATION REPAIR, BRAKE INSPECTION, AND FRICTION MATERIAL REPLACEMENT - SERVICE TIP FORD: 1993 FESTIVA 1993-1994 TEMPO 1993-1997 PROBE, THUNDERBIRD 1993-1999 ESCORT 1993-2000 CROWN VICTORIA, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 1998-2000 ESCORT ZX2 2000 FOCUS 1993-1996 BRONCO 1993-1997 AEROSTAR 1993-1998 F SUPER DUTY 1993-2000 ECONOLINE, EXPLORER, F-250 LD, RANGER 1995-2000 WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES LINCOLN: 1993-1998 MARK VIII 1993-2000 CONTINENTAL, TOWN CAR 2000 LS 1998-2000 NAVIGATOR MERCURY: 1993-1994 TOPAZ 1993-1997 COUGAR 1993-1999 TRACER 1993-2000 GRAND MARQUIS, SABLE 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER 1997-2000 MOUNTAINEER ISSUE This TSB serves as a guideline for servicing and diagnosing brake vibration, brake inspection, and brake friction material replacement. ACTION Refer to the following text and illustrations for servicing brakes.

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Several service procedures relating to brake vibration, system inspection, and pad/shoe replacement have been revised. Detailed descriptions of the service procedures are shown in Figure 1. Please note the changes for turning brake rotors. Criteria for sufficient rotor thickness before turning has been added to reduce the number of rotors that are replaced or turned to a dimension below the minimum thickness specification. Final Lateral Runout (LRO) and disc thickness measurements have also been deleted since proper rotor measurement and machine adjustment will insure that these dimensions are within specification.

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As part of this change, all car and light truck repairs will now be sequenced under labor operation 2001B, labor operation 2001A will remain in effect for medium and heavy duty truck applications. A unique labor operation for brake pad/shoe replacement, 2001B1, was added along with a consolidation of all turning operations into two labor operations, 2001B2xx and 2001B3xx. A comprehensive list of brake labor operations are listed in Figure 2. These new codes will be in the October Service Labor Time Standards release. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000

Technical Service Bulletin # 98-5A-52

Date: 980318

1996 Ford Truck Aerostar AWD V6-245 4.0L

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Brake Service - Service Tips Article No. 98-5A-52 03/18/98 BRAKES - BRAKE SERVICE - SERVICE TIPS LIGHT TRUCK: 1986-97 AEROSTAR ISSUE: Brake service, including both time and quality, may be further improved if "extra care is taken during brake service. Most Service Manuals do not contain the "finer points" of brake service. ACTION: Refer to the following Brake Service "Shop Tips" when servicing brakes. BRAKE SERVICE "SHOP TIPS" The following is "food for thought" when an Aerostar is brought in for any brake related roughness/pull concern. We have attempted to supplement the standard Service Manual procedures with aspects that are unique to this vehicle and questions that might not be obvious to ask the customer. First, make sure that you fully understand the customer's concern. Customers are not trained to diagnose vehicle problems and relay that information in a technical manner. The terminology the customer uses when describing his/her concern may be inappropriate or misleading for the problem the vehicle is experiencing. For example, a vehicle was brought in for service with the customer stating "the vehicle is hard to steer." After the technician spent a lengthy amount of time trying to pinpoint the problem and could not find anything wrong with the the vehicle's steering and handling capabilities, he accompanied the customer on a test drive. He asked the customer to reproduce the problem and discovered the actual problem was brake shudder. The customer had a difficult time "steering" the vehicle during hot brake applications when the vehicle had a tendency to shudder. If you are uncertain that you understand the customer's problem, don't guess, ask the customer to take you for a test drive and attempt to reproduce the problem. In the end, it will save not only your time, but the customer's as well. It is also a good idea to visually inspect the vehicle before servicing. Note anything that may contribute to or exaggerate the customer's concern, such as bent or distorted rims, the addition of a trailer hitch, or low tire pressure. Not only can bent or distorted rims exaggerate any roughness problem that the vehicle may have, it may also distort the rotor/drum much in the same way that over-torqued lug nuts will (discussed later). This, in turn, may cause brake shudder problems later down the road. If the vehicle has a trailer hitch, ask the customer how often he/she pulls the trailer? How heavy is the trailer? Is the trailer equipped with its own brakes? Pulling a trailer (especially if it is not equipped with trailer brakes) may cause Aerostar brakes to heat up quicker and consequently wear faster. Low tire pressure can exaggerate brake pull. Always verify proper tire inflation when diagnosing any vehicle pull or drift concern. If time permits, check/set the proper tire inflation (tire pressure is shown on the certification label on the driver's side door opening) and then have the customer demonstrate the pull/drift concern. Once you have a full understanding of the customer's concern and usage cycle (i.e., city driving with hard frequent braking vs. highway driving with moderate infrequent braking), you can begin to service the troubling components. When checking for dragging brakes, check for residual hydraulic pressure in the brake lines. If it is suspected that the residual pressure is being generated by the booster/master cylinder, generally you will find that both front brakes or both rear brakes are dragging as they are connected to the primary and secondary master cylinder circuits respectively. To check for residual pressure, first make three to five brake applications with vacuum on the booster (engine running). With the vehicle raised on a hoist and the wheels free to spin, crack the bleed on the suspected dragging caliper/wheel cylinder. If there is a "spurt" of brake fluid and a noticeable release of brake, there may be residual pressure in that brake. NOTE: FLUID SEEPAGE IS NORMAL; SPURTING FLUID WITH A CORRESPONDING RELEASE OF THE BRAKE WOULD MEAN RESIDUAL PRESSURE IN THE SYSTEM.

Repeating this procedure for the other brake in that circuit will verify a problem with the circuit versus just the single brake. If it is determined that there is residual pressure in the circuit and you cannot pinpoint the cause in another component, the booster output rod adjustment may be at fault. The Aerostar brake booster design does not allow for field adjustment of the output rod. ADJUSTMENT OF THE BRAKE BOOSTER OUTPUT ROD CAN ONLY BE PROPERLY PERFORMED AT THE MANUFACTURER. DO NOT ATTEMPT TO ADJUST THE OUTPUT ROD. Consequently, the booster must be replaced if there is residual pressure in the system and the booster is pinpointed as the root cause.

Once you start to disassemble the vehicle, observe and note the condition of the components. Keep track of anything out of the ordinary that might assist you in diagnosing and servicing vehicles in the future. Some things to look for are:

^

If you notice on the front brakes that one pad is wearing quicker than another it would suggest that the caliper is not sliding properly on its rails.

1996 Ford Truck Aerostar AWD V6-245 4.0L ^

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While looking at rear brakes, note the wear pattern on the drum braking surface. If it appears to be shiny and glazed, the pads may be contacting the drum. If you can still see the factory turn marks, the shoes may not be contacting the drum which may suggest an under-adjusted brake or a frozen wheel cylinder.

COMPONENTS TIPS Reference the Aerostar Service Manual, Section 06, for proper brake service procedures. Rotors and Drums: Resurface (as necessary) these components rather than just replacing them. Rotors should be replaced only if damaged or below minimum thickness specifications. Linings: If you are servicing the rotors and/or drums, you should inspect the linings as well. If there is a generous amount of lining material and it seems to be in good condition, you may reuse the pad assemblies. Linings may be used to a thickness of 1 mm. Calipers: Check if the pistons in the caliper seem to be binding or have seized. To understand the force required to push the caliper pistons back, use a set of tongue-in groove pliers. With an old pad in its service position (this will absorb any marring that the pliers may cause to the piston), use the pliers to push the pistons back. This method should help you understand the differences of required force from caliper to caliper. NOTE: IF YOU HAVE NEVER USED THIS METHOD BEFORE, IT IS RECOMMENDED TO FIRST TRY IT ON A KNOWN GOOD CALIPER TO GET A FEEL FOR THE "BASELINE" FORCE REQUIRED TO PUSH THE PISTONS BACK.

Rear Brake Assembly: When reassembling the rear brakes, use the recommended tool (D81L-1103-A) to set the lining-to-drum clearance. This will help assure that the brakes are in proper adjustment when the vehicle is returned to the customer. Also verify that the rear wheel cylinders are fully functional. This can be done after reassembly by applying the brake pedal and verifying that brake torque is being generated on both rear wheels.

SPECIAL MATERIALS

Lubricant: The specified lubricant used on mating brake components has changed. The new part number is D7AZ-19A331-A. This lubricant has a silicon base and should provide lubrication as well as better corrosion protection than the previous petroleum-based lubricant. It has a better temperature resistance and should stay in place much longer in a high heat area such as brakes. Also, petroleum-based lubricants do not react well with the rubber on the caliper slide pins and may eventually be harmful to the assembly. Some locations specifically require this silicon-based lubricant.

NOTE: THESE AREAS MUST BE FREE OF ALL DIRT AND CORROSION PRIOR TO APPLYING THE LUBRICANT.

They are:

1996 Ford Truck Aerostar AWD V6-245 4.0L

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^

On the knuckle - Specifically in the "V" grooves in which the caliper slide pins will rest, and where the caliper ends butt up against the knuckle (refer to Figure 1).

^

On the caliper slide pins - Lubricate the slide pins as well as the "V" groove to ensure proper lubrication all around (refer to Figure 1).

^

On the caliper - In the "V" grooves as well as the ends of the caliper which butt up against the knuckle to ensure proper caliper movement (refer to Figure 1).

^

On the knuckle where the inner pad rests - This area needs to be lubricated to prevent the pad from rusting to the knuckle which may reduce brake effectiveness and cause rotor wear on only one side, possibly resulting in brake shudder.

^

On the rear brake backing plate - Specifically where the shoe and lining assemblies contact the backing plate. Lubricate here to make sure the linings do not rust to the plate and prevent movement (i.e., when the parking brake is set overnight, if the shoes rust to the plate they would not be able to fully retract once the brake was released).

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Linings: Lining material is critically important to the proper function of the brake system. When diagnosing a problem, verify that the correct lining material is on the vehicle. Remember that the linings equipped on the Aerostar are specific for this vehicle application and any variation can change the stability, performance and control of the vehicle. ASSEMBLY All brake assembly procedures should be followed per the Aerostar Service Manual, Section 06. Remember to check, when assembling the component, the condition of all the mating surfaces such as: caliper-to-knuckle, rotor-to-hub (4X4 only), wheel-to-rotor, drum-to-hub or axle flange, drum-to-wheel, etc. Any foreign material on these mating surfaces can considerably distort the runout and/or roundness of the brake components, or in the case of the caliper, may reduce proper function. If there is any rust or foreign material on these surfaces, clean them with a stiff wire brush or the equivalent. In addition, remember that over-torquing of wheel lugs may distort brake components and possibly cause excessive runout or out-of-roundness. When assembling the wheel, be sure to use the recommended torque sticks (164-R0314) or an equivalent calibrated torque wrench. FINAL CHECK When the vehicle is completely reassembled, verify that the customer's concern has been addressed. Duplicate the customer's driving pattern on the verification drive, being careful not to do more harm than good. For example, if on the drive you have heated the brakes to the point that you can smell the linings, you have driven the vehicle too aggressively and should visually recheck the brakes before returning the vehicle to the customer. Hopefully, these service suggestions will further improve the service procedure and enhance customer satisfaction. If possible, educate the customer on exactly what was wrong and what was done to service the vehicle. Simple items like proper tire pressure and replacing components with only approved certified materials can save a lot of time and heartache in the future. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-26-17 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 390000, 703000, 790000

Technical Service Bulletin # 98-5A-13

Brakes - New Silicone Compound/Grease Article No. 98-5A-13 03/18/98 ^

BRAKES - DISC BRAKE CALIPER SLIDE GREASE NEW SPECIFICATION - SILICONE BRAKE CALIPER GREASE AND DIELECTRIC COMPOUND ONLY TO BE USED

^

BRAKES - DRUM - SHOE-TO-BACKING PLATE LUBRICATION - NEW LUBRICANT MATERIAL

^

BRAKES - PETROLEUM-BASED LUBRICANT MAY CAUSE SWELLING OF RUBBER PARTS - SERVICE TIP

^

LUBRICANT - SILICONE DIELECTRIC COMPOUND NEW APPLICATION - SILICONE BRAKE CALIPER GREASE AND DIELECTRIC COMPOUND

FORD: 1984-94 TEMPO 1984-96 MUSTANG, THUNDERBIRD 1985-96 CROWN VICTORIA, ESCORT 1986-96 TAURUS 1989-96 PROBE 1994-96 ASPIRE 1995-96 CONTOUR

Date: 980318

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LINCOLN-MERCURY: 1982-96 CONTINENTAL 1984-94 TOPAZ 1984-96 COUGAR 1985-96 GRAND MARQUIS 1986-96 SABLE, TOWN CAR 1987-89 TRACER 1991-94 CAPRI 1991-96 TRACER 1993-96 MARK VIII 1995-96 MYSTIQUE LIGHT TRUCK: 1983-96 RANGER 1986-96 AEROSTAR 1990-96 BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES 1991-96 EXPLORER 1993-96 VILLAGER 1995-96 WINDSTAR MEDIUM/HEAVY TRUCK: 1990-91 C SERIES 1990-96 F & B SERIES ISSUE: The use of petroleum-based grease as a lubricant in servicing disc brakes is no longer acceptable because it may be incompatible with the rubber material used in the disc brake system. If petroleum-based grease is used to lubricate any part of the disc brake system. it could cause rubber parts to swell if lubricant contacts the rubber material. ACTION: Refer to the following Servicing Procedures for details. DISC BRAKE SERVICING CAUTION: DO NOT USE PETROLEUM-BASED SERVICE GREASE (SUCH AS FORD DISC BRAKE CALIPER SLIDE GREASE D7AZ-19590A) TO LUBRICATE DISC BRAKE CALIPER SLIDE PINS OR RUBBER DUST BOOTS. PETROLEUM-BASED GREASE MAY CAUSE EPDM RUBBER TO SWELL.

When servicing any disc brakes, lubricate necessary components by applying Silicone Brake Caliper Grease and Dielectric Compound (D7AZ-19A331-A (Motorcraft WA-10)) or an equivalent silicone compound meeting Ford Specification ESE-M1C171-A. Refer to the appropriate Service Manual for specific service details.

DRUM BRAKE SERVICING

When servicing drum brakes, apply Silicone Brake Caliper Grease and Dielectric Compound (D7AZ-19A331-A (Motorcraft WA-10)) or an equivalent silicone compound meeting Ford Specification ESE-M1C171-A to the contact points between the brake shoes and the drum backing plates for lubrication.

NOTE: DISC BRAKE CALIPER SLIDE GREASE D7AZ-1959O-A SHOULD NO LONGER BE USED FOR DISC BRAKE CALIPER SLIDE LUBRICATION.

OTHER SERVICE APPLICATIONS

Existing inventory of D7AZ-19590-A may be used for all other Service Manual procedures. Once material is exhausted, all vehicle procedures specifying Disc Brake Caliper Slide Grease (D7AZ-19590-A) should use Silicone Brake Caliper Grease and Dielectric Compound (D7AZ-19A331-A).

PART NUMBER

PART NAME

D7AZ-19A331-A

Brake Caliper Grease And Compound

OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-21-2

1996 Ford Truck Aerostar AWD V6-245 4.0L

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WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000 Technical Service Bulletin # 97-19-4

Date: 970915

Brake and Rotor - Service Tips Article No. 97-19-4 09/15/97 BRAKES - BRAKE AND ROTOR SERVICE TIPS FORD: 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-98 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1993-94 TOPAZ 1993-97 COUGAR 1993-98 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1994-98 MARK VIII 1995-98 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 AEROSTAR 1993-98 RANGER, VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION ISSUE: This TSB article is intended to give a technician information regarding brake repairs to help reduce unnecessary repairs. ACTION: Refer to the following list when performing brake repairs. ^

Where rotors are the causal part, linings should only be replaced if they are damaged, e.g., cracked, taper wear, heavily grooved, etc., or if specifically instructed in a TSB.

^

Where linings are the causal part, rotors should not be machined unless they are heavily grooved or if specifically instructed in a TSB.

Other exceptions would include instances where the non-causal parts are found to be below minimum serviceable thickness or if the technician estimates that the parts will not last until the next service interval. Since these parts are classified as wear items (such as: linings, pads, rotors, and drums) replacement is not covered under warranty. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000

Technical Service Bulletin # 98-5A-11

Brakes - Elimination Of Sanding Rotors And Drums Article No. 98-5A-11 03/18/98 BRAKES - ELIMINATION OF SANDING ROTORS AND DRUMS - SERVICE TIP FORD: 1993 FESTIVA 1993-94 TEMPO

Date: 980318

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1993-97 CROWN VICTORIA, ESCORT, MUSTANG, PROBE, TAURUS, THUNDERBIRD 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1993-94 TOPAZ 1993-97 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER 1995-97 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 AEROSTAR, ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER, VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: Repeat brake repairs have been performed due to sanding of brake rotors and drums. The sanding of rotors and drums may have been done in reference to a Service Manual or TSB article which prescribes sanding as a repair, however, sanding is neither an effective nor lasting repair for customer complaints of brake roughness or noise. ACTION: Machine brake rotors and drums instead of sanding to help reduce brake roughness caused by one of the following conditions: ^

Rotor thickness variation and lateral runout

^

Lining or foreign material build-up

^

Drum out-of-round

NOTE: DO NOT MACHINE OR SAND ROTORS/DRUMS TO REDUCE OCCASIONAL BRAKE NOISE. IT IS NEITHER AN EFFECTIVE OR LASTING REPAIR.

OTHER APPLICABLE ARTICLES: NONE

SUPERSEDES: 96-22-2

WARRANTY STATUS: INFORMATION ONLY

OASIS CODES: 301000 Technical Service Bulletin # 98-5A-5

Hub-Mount Brake Rotor Machining Equipment Article No. 98-5A-5 03/18/98 ^

BRAKES - AVAILABILITY OF HUB-MOUNT BRAKE ROTOR MACHINING EQUIPMENT

^

BRAKE ROTOR MACHINING - AVAILABILITY OF HUB-MOUNT BRAKE ROTOR MACHINING EQUIPMENT

FORD: 1993 FESTIVA 1993-94 TEMPO 1993-97 PROBE, THUNDERBIRD 1993-98 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1993-94 TOPAZ 1993-97 COUGAR

Date: 980318

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1993-98 CONTINENTAL, GRAND MARQUIS, MARK VIII, SABLE, TOWN CAR, TRACER 1995-98 MYSTIQUE LIGHT TRUCK: 1993-96 BRONCO 1993-97 AEROSTAR, F SUPER DUTY, F-250 HD, F-350 1993-98 ECONOLINE, EXPLORER, F-150, F-250 LD, RANGER, VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE: Hub-mount brake rotor machining equipment from Rotunda is now approved for warranty and service use. Brake roughness consists of one or more of the following symptoms while braking: ^

Steering wheel vibration/nibble

^

vibration

^

Brake pedal pulsation

Brake roughness is caused by: ^

Uneven rotor wear known as Disc Thickness Variation (DTV). DTV is caused by excessive Lateral Run-Out (LRO) or overtorqued wheel lug nuts

^

Non-uniform lining transfer

ACTION: Use Rotunda Hub-Mount Lathe / Pro-Cut (201-00002) to service vehicles with brake roughness. The hub-mount lathe removes DTV, lining transfer, and on-vehicle rotor LRO. The hub-mount lathe has the following advantages over caliper-mount lathes: ^

Improved rotor LRO and "dishing" tolerances

^

Ability to machine rear rotors on live axles, except for trucks with dual rear wheels

^

Easier set-up

Refer to the Service Procedure for details. PART NUMBER

PART NAME

F6AZ-9L494-AA

High Temperature Nickel Anti-Seize Lubricant

OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 98-4-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 702300, 703000, 703400

Service Procedure 1.

Verify concern.

2.

Pre-checks to include: ^

Check OASIS and TSBs for vehicle-specific brake/vibration concerns

^

Visually inspect suspension bushings/ball joints

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^

Visually inspect tire conditions and pressure

^

Check wheel bearing end-play

3.

Remove wheel/tire.

4.

Remove caliper.

5.

For vehicles with two-piece hub/rotor: a.

Mark rotor and wheel stud for proper indexing during reassembly.

b.

Remove rotor.

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NOTE: THE ROTOR MUST HAVE SUFFICIENT THICKNESS AFTER MACHINING TO BE OVER THE MINIMUM THICKNESS SPECIFICATION

6.

Measure rotor thickness and record measurement. Replace rotor if below the minimum thickness specification cast in the rotor.

CAUTION: DO NOT USE ABRASIVE SANDING DISC SINCE IT WILL REMOVE METAL FROM MOUNTING SURFACES AND ADVERSELY AFFEC 7.

Remove corrosion from wheel mounting surface, both rotor mounting surfaces, and hub mounting surface. A die grinder with a Scotchbrite(R) sur

8.

For vehicles with two-piece hub/rotor, reinstall rotor onto hub, aligning with marks from Step 5a.

NOTE: READ THE ENTIRE OPERATING MANUAL AND VIEW THE VIDEO SHIPPED WITH THE LATHE BEFORE INSTALLING, OPERATING, 9.

Machine rotors using the Rotunda Hub-Mount Brake Lathe / Pro-Cut (201-00002). a.

Install hub adapter and silencer belt (where applicable).

b.

Install cutting lathe.

NOTE: TOTAL INDICATED READING (TIR) TARGET IS 0.000 mm, MAXIMUM IS O.O6 mm (0.003"). c.

Adjust lathe oscillation using a dial indicator.

NOTE: DEPTH OF CUT SHOULD BE BETWEEN 0.10 AND O.2O mm (0.004 AND 0.008"). LIGHTER CUTS WILL CAUSE THE BIT TO HEAT UP A d.

Center cutting head, adjust cutting bits, install chip deflector.

e.

Machine rotor.

f.

Measure and record rotor thickness.

NOTE: TARGET LRO IS 0.000 mm, MAXIMUM IS O.05 mm (0.002"). g.

Install dial indicator, measure and record rotor LRO. Remove dial indicator.

h.

Remove lathe and silencer belt.

10.

Remove metal shavings.

11.

Remove the adapter.

12.

For vehicles with two-piece hub/rotors: a.

Remove rotor from hub.

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b.

Remove metal shavings from hub and rotor mounting surfaces and from ABS sensors.

c.

Apply High Temperature Nickel Anti-Seize Lubricant (F6AZ-9L494-AA) to hub mounting surface to prevent future corrosion.

d.

Match marks on rotor and hub and assemble rotor to hub.

Install pads and calipers.

NOTE: USING AN IMPACT TOOL WITHOUT AN ACCUTORO(R) SOCKET WILL LEAD TO UNEVENLY TORQUED LUG NUTS. THIS CAUSES

14.

Install wheels using impact guns equipped with Rotunda AccuTorq(R) sockets. Use a torque wrench on locking lug nuts.

15.

Check brake operation before returning to customer.

Support Telephone Numbers 1.

Lathe Administration Support: (800) 768-8632

2.

Pro-Cut Technical Support: (800) 543-6618 Reference list for Pro-Cut car labor operations:

^

A = Aspire

^

B = Escort/Tracer

^

C = Probe

^

D = Contour/Mystique

^

E = Mustang

^

F = Taurus/Sable

^

G = Thunderbird/Cougar

^

H = Crown Victoria/Grand Marquis

^

I = Continental

^

J = Mark VIII

^

K = Town Car

^

L = Festiva

1996 Ford Truck Aerostar AWD V6-245 4.0L ^

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M = Tempo/Topaz

Reference list for Pro-Cut light truck labor operations: ^

AA = Villager

^

AB = Windstar

^

AC = Aerostar 4X2

^

AD = Aerostar 4X4

^

AE = Ranger 4X2

^

AF = Ranger 4X4

^

AG = Explorer/Mountaineer 4X2

^

AH = Explorer/Mountaineer 4X4

^

AI = Econoline

^

AJ = F-250 HD/F-350 4X2

^

AK = F-250 HD/F-350 4X4

^

AL = F-Super Duty

^

AM = F-150/F-250 LD 4X2

^

AN = F-150/F-250 LD 4X4 And Bronco

^

AO = Expedition/Navigator 4X2

^

AP = Expedition/Navigator 4X4

^

AQ = Super Duty F SeriesTechnical Service Bulletin # NHTSA98E010000

Recall 98E010000: Brake Rotor Cracking

Date: 980407

1996 Ford Truck Aerostar AWD V6-245 4.0L

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Year: 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997 Make: FORD TRUCK Model: AEROSTAR Year: 1994 Make: MAZDA TRUCK Model: PICKUP Year: 1990 Make: FORD TRUCK Model: BRONCO II Year: 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994 Make: FORD TRUCK Model: RANGER Year of Recall: '98 Type of Report: Equipment Potential Number of Units Affected: 23500 Summary:

Equipment Description: Brake rotors for use on Ford and Mazda trucks. Cracked castings caused cracks to appear on the outer diameter of the rotor hat o Loss of braking can result.

Aimco will reimburse consumers/installers for the cost of replacement rotors and installation. Consumers are requested to return to the location where the

Owner notification is expected to begin during April 1998. Owners who do not receive the free rotors within a reasonable time should contact Aimco at 1