Ford Falcon. Manual — part 66
206-04-2
Rear Disc Brake 206-04-2
SPECIFICATIONS
General Specifications
Description
Specification
Rear disc brake minimum
14.5mm (0.57in)
thicknessª
Lubricants
High melting point grease Dow Corning 44/Niglube
Rx2
Pad
Lining wear limit
1.0mm
Material
JBUF85FF
Torque Specifications
Description
Nm
Brake caliper bolts
103
Brake disc shield bolts
11
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206-04-3
Rear Disc Brake 206-04-3
DESCRIPTION AND OPERATION
Rear Disc Brake
Rear Disc Brake System Components
Parking Brake
The parking brake utilizes a cable operated rear drum
system. For additional information, refer to Section
206-05.
Item
Description
1
Knukle
2
Wheel hub
3
Washer
4
Nut
5
Rotor
6
Brake Caliper
7
Bolt
The rear wheel disc brake assembly consists of a
rotor mounted on the outer face of the axle shaft
flange and a single piston floating head caliper. A
splash shield, used primarily to prevent road
contaminants from contacting the inboard rotor and
pad surface is also mounted on the anchor bracket.
The outboard rotor and pad surfaces are protected by
the road wheel.
Service Brake
When the brake pedal is applied, brake fluid is
displaced into the caliper bore moving the piston
outward. This action forces the inner pad assembly
against the rotor. The resultant reaction forces the
caliper body and outboard pad assembly inward
against the rotor. Braking torque is transferred from
the outer and inner pad assemblies to the caliper
mounting bracket. When the brake pedal is released,
the piston seal retracts the piston a small amount
allowing the pads to release the clamping force.
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206-04-4
Rear Disc Brake 206-04-4
DIAGNOSIS AND TESTING
Brake Calipers
Refer to Section 206-00.
Inspection
1. Clean all residue from disc pad guide surfaces on
anchor bracket and caliper housing assembly.
NOTE: Always replace both axle caliper pads as
a set.
2. Inspect inner and outer pads. Lining wear limit is
1.0 mm.
3. Inspect anchor bracket. Replace anchor bracket if
corroded, worn or damaged.
4. Clean piston, housing and bleed screw. Use only
clean denatured alcohol for cleaning. Dry, filtered
compressed air should be used to dry all
components and blow out all passages in the
caliper housing and bleed screw. Care should be
taken to keep alcohol and debris away from eyes.
CAUTION: All components must be kept
away from any type of mineral oil as it will
damage rubber components.
5. Inspect piston. Replace piston if scoring, nicks,
corrosion, wear or damage is evident.
6. Inspect housing. Replace housing if bore is
scored, corroded, worn or damaged.
7. Lubricate seal and housing bore with silicone
grease or brake fluid.
8. Lubricate piston with brake fluid.
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206-04-5
Rear Disc Brake 206-04-5
REMOVAL AND INSTALLATION
2. Remove caliper mounting bolts.
Brake Caliper Body
Removal
NOTE: Where the use of brake fluid is required, use
only new, clean fluid to the correct specification, from
a sealed container.
1. Raise the vehicle and remove the wheel.
2. Use wheel nut to hold disc in place.
3. Remove banjo bolt and hose end. Discard
washers. Plug housing inlet port and hose end to
prevent contamination ingress or fluid loss.
4. Remove guide pin bolts (items 1 and 2) and
discard.
Installation
3. Lift caliper free of rotor.
1. Place caliper housing assembly into its operating
4. To install reverse steps 1-3.
position. If springs are sticking through caliper
housing inspection hole, lift caliper housing and
Rear Brake Hose
make necessary corrections to ensure springs are
fully retained by housing.
Removal
2. Install new guide pin bolts.
3. Assemble banjo bolt, washers and hose end then
screw into housing inlet port. Torque guide bolts
to 28-34 Nm. Torque banjo bolt to specification.
NOTE: Ensure hose is engaged to bracket prior to
fitment of banjo bolt. Check routing for correct
clearance on completion.
4. Bleed brakes ensuring that fluid reservoir is not
emptied. Start engine and pump brake pedal
slowly and firmly three times to ensure piston and
disc pads resume normal operational position.
Torque bleed screw to 9-14 Nm. Check for fluid
leakage and rectify if any found. Check fluid level
in master cylinder reservoir and fill to specified
level with new brake fluid.
Item
Description
NOTE: All hardware must be correctly installed
1
Rivot
and torqued to specification.
2
Rear Tube Connection
5. Install wheel and torque nuts to specification.
3
Grommet
Brake Caliper Assembly
4
Banjo Bolt
Removal and Installation
1. Disconnect rear brake tube connection.
1. Repeat steps 1 & 2 of brake caliper body removal. 2. Drill out rivot.
3. Remove
grommet.
4. Remove banjo bolt.
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