Article No. 87-13-20

BRAKE - FRONT DISC - "GROANING/GRINDING" NOISE DURING LIGHT BRAKE APPLICATION - VEHICLES BUILT BEFORE 03/04/87

NOISE - "GROANING/GRIN DING" - DURING LIGHT BRAKE APPLICATION - VEHICLES BUILT BEFORE 03/04/87

LIGHT TRUCK: 1986-87 AEROSTAR

ISSUE: A "groaning/grinding" noise from the front of the vehicle at slow speeds (below 15 mph/24 km/h) during light braking may be caused by the design of the existing brake components. The noise may be improperly diagnosed as a bad wheel bearing or worn out disc brake pads. The "groaning/grinding" noise can only be heard from inside the vehicle.

ACTION: To correct this, install current design brake caliper and lining assemblies, front caliper brake hoses and two damper and clamp assemblies. On vehicles built before 09/15/86, install new rotor assemblies. Refer to the following step-by-step service procedure.

1. Raise vehicle on hoist.

NOTE: The lower arms need to be supported by the hoist or axle stands to allow upper arm to rotate off rebound bumper.

2. Remove both front wheel and tire assemblies.

3. Remove both front caliper and lining assemblies. Refer to Aerostar Shop Manual, Section 2-03-04.

4. Remove both front caliper brake hoses. Refer to Aerostar Shop Manual, Section 2-01-24.

5. Remove both front rotor assemblies on vehicles built prior to 09/15/86. Refer to Aerostar Shop Manual, Section 1-03-6.

NOTE: Damper and clamp assemblies are marked with "R" for right hand (passenger's side) or "L" for left hand (driver's side) installation.

Figure 17:

6. Position damper assemblies on top of upper control arms with long ends of weights pointing forward, Figure 17. Make sure the single inboard attachment is resting on rear leg of upper control arm.

7. Position clamp(s) on bottom side of upper control arm(s). Start, by hand, all three (3) bolts that attach clamp(s) to damper(s).

8. Tighten all bolts about 1/2 to 3/4 of the way.

9. Hold damper(s) in correct position.

^ The inboard attachments resting on rear leg of control arm.

^ The two (2) outboard attachments resting on flattened area of control arm with mounting bracket snuggled up against edge of upper ball joint housing.

10. Tighten inboard bolt first. Then tighten two (2) outboard attachment bolts. Torque bolts to 25 ft.lbs. (34 N-m).

11. Make sure damper weight(s) do not touch upper ball joint or either leg of upper control arm. Reposition if necessary.

12. On vehicles built before 09/15/86, install two (2) new rotor assemblies (E3TZ-1102-A).

13. Install two (2) new front caliper brake hoses (E8TZ-2078-B/R.H., and E8TZ-2078-A/L.H.).

14. Install two (2) new front brake caliper (E8TZ- 2B120-B/R.H., and E8TZ-2B121-B/L.H.) and new disc brake pad assemblies (E8TZ-2001-B).

15. Bleed the brake hydraulic system. Refer to Aerostar Shop Manual, Section 2-01-20.

16. Install both front wheel and tire assemblies.

17. Lower hoist and release vehicle.

PART NUMBER PART NAME CLASS

E3TZ-1102-A Rotor AM
E8TZ-2B120-B Caliper - R.H. B
E8TZ-2B121-B Caliper - L.H. B
E8TZ-2078-B Brake Hose - R.H. C
E8TZ-2078-A Brake Hose - L.H. C
E79Z-3C156-A Damper Assembly C
R.H.
E79Z-3C157-A Damper Assembly - C
L.H.
N605905-S101 Bolts - Package of 6 S
E79Z-3C162-A Clamp - R.H. C
E79Z-3C163-A Clamp - L.H. C
388949-S Washer Brake Hose - B
Package of 10
E8TZ-2001-B Brake Disc Pads

OTHER APPLICABLE ARTICLES: None
WARRANTY STATUS: Reimbursable within the provisions of the Warranty and Policy Manual
OPERATION: SP871320A
TIME: 1.3 Hrs. DLR. CODING: Basic Part No. 2001 - Code: 56