Service Procedure

1. Check and adjust brake pad clearances and caliper knuckle clearances as follows:

a. Remove the pins from the caliper.





b. While holding the caliper in place against the bottom pin rails, Figure 1, measure the clearance between the caliper and the top pin rails. Clearance should be a minimum of 0.3B mm (0.015").

c. If the clearance is insufficient, replace the caliper and measure again. If clearance concern still exists, replace the knuckle.

NOTE:
CHECK THE CLEARANCE ON THE NEW KNUCKLE BEFORE INSTALLATION.

d. After measuring the caliper/knuckle for proper clearances, remove both calipers and inner pad assemblies.

e. Remove the anti-rattle clip from the inner pad.





f. Reinstall pad and check the side and end clearances with a feeler gauge (Figure 2).





g. If the pad clearances are within specification, go to Step 1h. If the pad clearances are not to the required dimensions, file the steel backing plate. File material at ends of shoes, removing equal amounts from both sides or ends (Figure 3).

CAUTION:
DO NOT GRIND THE STEEL BACKING PLATE. IT IS POSSIBLE TO REMOVE TOO MUCH MATERIAL WHEN GRINDING.

h. Check the tab clearances and install anti-rattle clip on the lower pad tab (Figure 2).

CAUTION:
MAKE SURE THE LUBRICANT DOES NOT GET ON THE ROTORS, LININGS, OR ON THE CALIPER PISTON BOOTS.

2. During reassembly:

^ Clean the caliper slide surfaces of corrosion, contamination, and burrs with a wire brush or portable wire wheel

^ Polish with crocus cloth

^ Lubricate and corrosion protect by applying a light coat of Silicone Brake Caliper Grease and Dielectric Compound (D7AZ-19A331-A), or equivalent meeting Ford specification ESE-M1C171-A, to the inner knuckle top and bottom pad groove and caliper rails (Figure 1)

^ Replace the caliper pins with new Caliper Pins (F2TZ-2C150-A)

NOTE:
THE EXPLORER IS ALREADY EQUIPPED WITH THE NEW RADIUS ARM BUSHINGS.

3. Inspect the right and left side radius arm bushings for cracking, splitting, or wear. Replace the right and left side arm bushings with new Radius Arm Bushings (F1TZ-3B203-B), medium brown color, if necessary. Refer to the appropriate Service Manual, Section 04-01C, for service details.