Ford Falcon. Manual — part 64
206-03-5
Front Disk Brake
206-03-5
DIAGNOSIS AND TESTING
Front Disc Brake
Refer to Section 206-00
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206-03-6
Front Disk Brake
206-03-6
REMOVAL AND INSTALLATION
3. Using (G-clamps as shown), tighten until each
Brake Pads
piston bottoms on each bore.
Removal
NOTE: Ensure that one end of the G-clamp rests
on (or is adjacent to) the brake hose attaching
WARNING: Although original equipment pad
bolt head, and the other against the outer pad.
material is asbestos free. If non genuine pads are
DO NOT exert excess force on the clamps as
used, the following applies:
damage to steel pistons may result.
Asbestos fiber dust may be present on brake
and clutch assemblies and is hazardous to
health if inhaled.
Brake and clutch assemblies should be
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.
Item
Description
1. Clean and remove master cylinder reservoir cap.
1
Pad Abutment Bracket
Loosen front brake line connection at the master
2
Guided pin and boot assembly
cylinder, allowing fluid to bleed into a container
3
Guide pin bolt
until master cylinder reservoir is one-third full. Re
tighten line connection and replace master
4
Piston
cylinder cap.
5
Piston dust boot
6
Pad abutment shim
WARNING: Brake fluid will damage
paintwork.
7
Pads
NOTE: Do not completely remove brake line or
4. Using a suitable size open-end spanner to hold
empty the reservoir or it will be necessary to
the lower guide pin (7), remove and discard the
bleed the system.
guide pin bolt (3).
NOTE: Discard the fluid removed. DO NOT
NOTE: Old bolts must not be re-used, as they are
RE-USE.
vital safety components that have a micro
encapsulated adhesive on the bolt thread.
NOTE: Removal of the fluid is necessary to
prevent reservoir overflow when the caliper piston 5. Disengage brake hose grommet from bracket
is pushed back in its bore during pad
attached with caliper mounting bolt.
replacement.
6. Swing caliper housing about the existing guide pin
2. With vehicle raised evenly on a hoist or jack
until housing is clear of pads.
stands, mark relationship of wheel to hub and
7. Remove worn pads (7&8) from abutment bracket
remove the front wheels.
(7) and inspect condition of brake disc. Discard
Using wheel nuts secure rotor to hub during work.
end abutment shims (6).
NOTE: If more than one brake requires service,
8. Check guide pins for free movement in abutment
work on only one brake at a time. Pad
bracket. If there is restriction of movement,
assemblies, must always be replaced in both
replace guide pins and/or guide pin boots.
brakes.
Including high lube grease.
9. Clean any dirt from both the piston face, which
contacts the inner pad, and the caliper head area
that contacts the outer pad.
10. Inspect caliper assembly for fluid leaks or
damage.
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206-03-7
Front Disk Brake
206-03-7
REMOVAL AND INSTALLATION (Continued)
Installation
Front Brake Hose
1. Replace end abutment shims (6) in abutment
bracket (1), ensuring they are secure and clear of Removal
the rotor being careful not to bend them.
2. Install the inner (7) and outer (8) pads to the
abutment bracket (1), against the inner and outer
surface of the brake disc respectively.
3. Lower the brake calliper housing, ensuring that:
the piston boots (4&5) do not get caught
between the piston and inner pad (7).
4. Install and tighten the new guide pin bolt (3) to the
correct torque specification.
NOTE: Do not wedge anything between the
guide pin hex and the caliper as it could cause
incorrect alignment of the free sliding of the
caliper relative to the anchor plate.
5. Refit brake hose grommet to bracket attached to
Item
Description
caliper bracket, as previously positioned.
1
Clip
6. Replenish the brake fluid in the master cylinder
2
Brake tube connector
with fresh specified fluid.
3
Banjo bolt
7. Pump the brake pedal several times to position
the pad assemblies.
4
Grommet
8. Check for fluid leakage at all connections under
1. Remove banjo bolt and washers.
pedal pressure.
2. Remove grommer from hose positioning bracket.
9. Re-check fluid level in master cylinder reservoir.
3. Disconnect the brake tube connector.
10. Remove wheel nuts.
4. Remove clip (4).
11. Reinstall wheels, aligning marks made prior to
5. Remove hose assembly.
removal and remove jack stands or lower hoist.
Installation
12. Tighten wheel, securing nuts to the specified
torque.
1. Install banjo bolt and new washers. Torque to
specification.
13. Road test vehicle and make several light
60-0km/h stops to seat the linings. (The vehicle
2. Install grommet into hose positioning bracket.
may pull slightly to one side for the first few
3. Install hose into body bracket and install clip.
applications. This is normal until linings are
NOTE: Ensure hose is engaged to bracket prior to
seated)..
fitment of banjo bolt. Check routing for correct
clearance on completion.
4. Connect brake tube and torque to specification.
5. Bleed as outlined in procedure.
Brake Caliper Body
Removal
1. Raise and support the vehicle to ensure it is
stable and secure. Mark the relationship of the
wheel and the rotor and remove wheel.
2. Place a drain tray beneath caliper assembly.
Loosen and remove attaching bolt and hose end.
Discard washers and plug caliper body inlet port
and hose end to prevent contamination or fluid
loss.
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206-03-8
Front Disk Brake
206-03-8
REMOVAL AND INSTALLATION (Continued)
3. Disconnect hose. Discard copper sealing rings.
2. Remove the caliper assembly from the spindle
and the rotor, as previously described in this
section. If the caliper does not require servicing, it
is not necessary to disconnect the brake hose.
Position the caliper out of the way, and support it
with a wire to avoid damaging the caliper or the
hose. Handle the rotor, linings and caliper
assemblies carefully to avoid deformation, nicking,
scratching or contamination.
3. Remove the rotor from hub.
Installation
1. Position the rotor on the axle flange.
NOTE: Ensure that all mounting surfaces are
clean and free from contamination which could
cause possible disc runout.
Installation
2. Mount the caliper assembly on the spindle
following the Disc Brake Caliper Assembly
1. Assemble caliper body to abutment bracket (1) by
Installation procedure in this section.
securing upper guide pin using a new guide pin
bolt (3).
3. Install the wheel.
2. Lower the brake caliper housing, ensuring that:
1. the piston boots (4&5) do not get caught
between the piston and inner pad (7).
3. Install and tighten the new guide pin bolt (3) to the
correct torque specification.
NOTE: Ensure hose is engaged to bracket prior to
fitment of banjo bolt. Check routing for correct
clearance on completion.
NOTE: Do not wedge anything between the guide
pin hex and the caliper as it could cause incorrect
alignment of the free sliding of the caliper relative
to the anchor plate.
4. Reconnect new brake hose, using new, dry,
sealing washers. Tighten attaching bolt to the
correct torque specification ensuring hose routing
is removed.
5. Bleed brake system, refer to Brake system Bleed
in this section.
Brake Disc
Removal
1. Remove the wheel and tyre from the hub.
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