Ford Falcon. Manual — part 67
206-04-6
Rear Disc Brake 206-04-6
REMOVAL AND INSTALLATION (Continued)
Installation
4. Position a C-clamp so that one end rests on rear
of caliper housing and the other end against outer
1. Install high tensile rivot.
disc pad. Tighten clamp until piston bottoms in
base of caliper housing.
2. Connect tube to hose end.
3. Install hose grommet into bracket.
5. Remove and discard upper guide pin bolt.
4. Install banjo bolt through hose and into caliper.
6. Rotate caliper housing about lower caliper
NOTE: Ensure hose is engaged to bracket prior to
mounting bolt and guide pin. Be careful not to
fitment of banjo bolt. Check routing for correct
strain hose.
clearance on completion.
7. Remove inner and outer pads.
NOTE: Ensure fitment of new copper washers.
NOTE: Always replace both axle caliper pads as
a set.
Brake Pads
8. Clean all residue from disc pad guide surfaces on
anchor bracket and caliper housing.
Removal
9. Inspect guide pins for free movement in anchor
WARNING: Although original equipment pad
bracket. Replace guide pins or boots if corroded
material is asbestos free. If non genuine pads are
or damaged.
used, the following applies:
Installation
Asbestos fiber dust may be present on brake
1. Install new pads on anchor bracket. Apply
and clutch assemblies and is hazardous to
approximately 0.1 gram of AKB-100 grease (or
health if inhaled.
equivalent) to pad abutment surfaces on the
Brake and clutch assemblies should be
anchor bracket.
cleaned using a vacuum cleaner
recommended for use with asbestos fibers
such as a brake/clutch/service vacuum. The
bag must be labeled per OSHA instructions,
sealed, and the trash hauler notified as to the
bag’s contents.
If the vacuum suitable for asbestos is not
available, cleaning should be done wet. If dust
generation is still possible, technicians should
wear goverment-approved toxic dust purifying
respirators. Failure to follow these
instructions may result in personal injury.
1. Siphon approximately two-thirds of the total fluid
capacity from the master cylinder reservoir.
Discard the fluid (different to front brake).
2. Rotate caliper housing into its operating position.
2. Raise the vehicle and remove wheels.
3. If springs are sticking through caliper housing
3. Install two wheel nuts to retain rotor.
inspection hole, lift caliper housing and make
necessary corrections to ensure springs are fully
retained by housing.
4. Install new upper guide pin bolt and torque to
28-34 Nm.
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206-04-7
Rear Disc Brake 206-04-7
REMOVAL AND INSTALLATION (Continued)
5. Top up master cylinder.
Beam Axle Brake Disc
6. Start engine and pump brake pedal slowly and
Removal
firmly three times to ensure piston and disc pads
resume normal operating position.
1. Raise
the
vehicle.
7. Check for fluid leakage and rectify if any found.
2. Wipe all dirt and grease from the brake pipe union
Check fluid level in master cylinder reservoir and
and disconnect the union.
fill to specified level with new brake fluid.
3. Detach the flexible hose from the splash shield
8. Remove nuts retaining rotor and install wheels.
bracket and plug the pipe and hose.
9. Lower vehicle and torque wheel nuts to
4. Remove the three screws attaching the splash
specification.
shield to the axle flange.
Installation
Brake Disc
1. Position the splash shield and install the attaching
Removal
screws.
1. Raise the vehicle and remove the rear wheels.
2. Fit the flexible hose to the splash shield bracket
and secure it with the locknut.
2. With the park brake control released disconnect
the park brake cable at the equalizer.
3. Remove the dust plugs and fit the pipe to the
hose.
4. Bleed the brakes as described in Section 206-00.
5. Lower the vehicle.
3. Disconnect the cable from the levers.
4. Remove the caliper head attaching bolts and
remove the caliper assembly from the rotor and
mounting bracket.
CAUTION: Do not allow the caliper to
hang from the hydraulic line.
5. Remove the screw securing the rotor to the axle
flange and remove the rotor (for beam axle only).
Installation
1. Position the rotor on the axle flange, ensuring that
all mounting surfaces are clean and free from
contamination which could cause possible disc
run-out. Install the securing screw.
2. Position the caliper correctly over the rotor and
slide straight into location until caliper head bolt
holes align with their respective holes in the
mounting bracket.
3. Install caliper mounting bolts and torque to
specification.
4. Connect the park brake cables to the levers and
the equalizer. Adjust the park brake as described
in Section 206-05
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206-04-8
Rear Disc Brake 206-04-8
DISASSEMBLY AND ASSEMBLY
Brake Caliper
Disassembly
4. Remove piston (item 12). Pack a clean shop towel
Item
Description
between piston and housing finger then apply low
1
Bleed Screw
air pressure at housing inlet port to remove piston.
2
Caliper Housing
CAUTION: Apply light air pressure
3
Anchor Bracket
initially and progressively increase until piston
4
Outer Disc Pad
is forced out of bore. While removing piston
5
Boot
keep hands away from piston/housing region
to avoid personal injury, as the piston may
6
Guide Pin
develop considerable force due to air
7
Inner Disc Pad
pressure.
8
Boot
5. Remove boot and seal using a small, pointed tool
9
Piston
as per Section 206-03. Be careful not to damage
10
Seal
the bore or seal groove. Discard.
11
Lower Mounting Bolt
6. Remove bleed screw (item 15) and dust cover
(item 16). Discard dust cover.
12
Inlet Port
13
Upper Guide Pin Bolt
Assembly
1. Remove brake caliper as described in this
1. Lubricate seal (item 13) and housing bore with
section.
silicone grease or brake fluid.
2. Remove housing assembly (item 9), guide pins
2. Lubricate piston with brake fluid.
(items 3 and 4) and boots (items 5 and 6).
3. Install new seal (item 13) into housing bore seal
Discard boots. Plug anchor bracket (10) colette
groove and ensure that it is not twisted.
pinholes (A) to prevent contamination ingress.
NOTE: Ensure hose is engaged to bracket prior to
3. Remove disc pads (items 7 and 8).
fitment of banjo bolt. Check routing for correct
clearance on completion.
G86759 en
206-04-9
Rear Disc Brake 206-04-9
DISASSEMBLY AND ASSEMBLY (Continued)
4. Install new boot (item 14) and piston. Install boot
8. Install disc pads on anchor bracket with outer disc
over open end of piston and feed along piston
pad with clip-on insulator toward caliper housing
length towards closed end. Fully extend boot
finger and inner disc pad with lining wear sensor
away from piston closed end with boot still on
toward caliper piston.
piston ground surface. Install boot into housing
bore boot groove and ensure full engagement.
5. Slowly enter piston into bore by hand, then apply
steady pressure by hand to piston and press until
piston is fully seated in the bore. This process will
ensure that boot and seal are correctly positioned
in conjunction with no piston/housing bore
scoring.
6. Inspect piston and boot. Check that boot is
properly engaged in piston groove correctly.
7. Assemble dust cover and bleeder screw, then
screw into housing.
G86759 en
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