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Home >> Ford >> 1995 >> Windstar V6-232 3.8L >> Repair and Diagnosis >> Brakes and Traction Control >> Disc Brake System >> Brake Caliper >> Service and Repair >> Removal and Installation >> Front
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Front

REMOVAL
1. Raise vehicle on hoist.
2. Remove wheel and tire assembly from rotor mounting face. Do not damage bleeder screw fitting during removal.
3. Mark disc brake caliper to make sure it is installed on correct front wheel hub and spindle during installation.
4. Disconnect flexible brake hose from disc brake caliper. Remove hollow retaining bolt that connects hose fitting to disc brake caliper. Remove hose assembly from disc brake caliper and plug hose.
5. Remove two guide pin bolts.
6. Lift disc brake caliper off front disc brake rotor using rotating motion.

CAUTION: Do not pry directly against metal piston. Damage to piston will occur.

INSTALLATION
1. Retract caliper piston fully in caliper piston bore. Make sure inner and outer pads are properly positioned. Make sure lining material is facing rotor. Position disc brake caliper over front disc brake rotor. Install guide pin bolts through front disc brake caliper holes into disc brake caliper locating pins and hand start.

NOTE: Make sure correct disc brake caliper, as marked during removal, is installed on correct front wheel hub and spindle. The front disc brake caliper bleed screw should be positioned on top of disc brake caliper when assembled on vehicle.

2. Tighten two guide pin bolts to 34 Nm (25 ft lb).
3. Remove plug and install brake hose on disc brake caliper with new copper washer on each side of fitting outlet. Insert retaining bolt through washers and fittings. Tighten to 47-63 Nm (35-46 ft lb).
4. Bleed brake system. Always Replace rubber bleed screw cap after bleeding.
5. Fill brake master cylinder.
6. Install wheel and tire assembly. Tighten lug nuts to 113-153 Nm (84-112 ft lb). Use torque wrench instead of an impact tool.

CAUTION: Failure to tighten wheel hub bolt nuts with torque wrench in star pattern may result in high rotor runout, which will speed up the development of brake roughness/shudder/vibration.

7. Lower vehicle.
8. Pump brake pedal prior to moving vehicle to position brake linings.
9. Road test vehicle.
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