Ford Falcon. Manual — part 65

206-03-9

Front Disk Brake

206-03-9

DISASSEMBLY AND ASSEMBLY

Brake Caliper

Disassembly

2. Remove brake pads (10&11) from abutment

Item

Description

bracket.

1

Sealing Ring

2

Caliper Body

3

Guide Pin Bolt

4

Bleed Screw Sealing Ring

5

Bleed Screw

6

Guide Pin

7

Guide Pin Boot

8

Piston Boot

9

Piston

10

Inner Pad Assembly

11

Outer Pad Assembly

12

Pad Abutment Shim

13

Abutment Bracket

3. Remove abutment bracket from mounting

knuckle. Remove abutment shims (12) from

1. Remove Brake Caliper. For additional information,

abutment bracket.

refer to Section 206-03.

4. Withdraw guide pins (6) and boots (7) from

NOTE: Ensure hose is engaged to bracket prior to

anchor plate. Separate boots from pins.

fitment of banjo bolt. Check routing for correct

clearance on completion.

G96757 en

206-03-10

Front Disk Brake

206-03-10

DISASSEMBLY AND ASSEMBLY (Continued)

5. Remove pistons (9) by placing a spacer between

4. Coat piston boots (8) in specified grease and

the pistons and the caliper fingers and applying

place boot over end of piston. Position each

air at the inlet port of the caliper housing until

piston into caliper housing, seating each boot into

each piston is forced out of the bores.

groove in caliper bore. Ensure the boot is

squarely and firmly seated in groove.

CAUTION: Inject air lightly and

progressively increase the pressure until the

piston is forced out of the bore. This

procedure is advisable to avoid physical

injury, as the pistons may develop

considerable force due to sudden pressure

increases.

6. Remove rubber piston boot (8) from bore.
7. Remove piston seal (1) from bore taking care not

to damage bore or seal locating groove.

5. Push each piston squarely into each bore by hand

until fully seated.

6. Ensure boot is fully seated in piston a caliper

grooves.

8. Remove bleed screw (5). Discard bleed screw

seal ring (4).

9. Inspect all parts as described in Cleaning and

Inspection.

Assembly
1. Place caliper assembly on a clean bench area

with the open end of caliper body (2) up.

7. Fit new bleed screw sealing ring (4).Reinstall

2. Lubricate cylinder bores and pistons (9) with

bleed screw (5).

specified fluid.

8. Lubricate guide pins (6) with specified grease.

3. Fit new seals (1) by positioning seal at one area

Install new guide pin boots (7) onto the guide

in the groove and gently work around the cylinder

pins.

bore with a finger until properly seated. Check to

be sure the seal is not twisted or rolled in its

groove.

G96757 en

206-03-11

Front Disk Brake

206-03-11

DISASSEMBLY AND ASSEMBLY (Continued)

9. Reinstall guide pins into anchor plate, pushing the

guide pin boot over its groove. Ensure there is no

air trapped inside the boot.

10. Ensure abutment bracket mounting surfaces are

clean. Reinstall abutment bracket over brake disc,

securing anchor plate to mounting knuckle.

G96757 en

206-04-1

Rear Disc Brake 206-04-1

SECTION : 206-04 Rear Disc Brake

VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS

PAGE

SPECIFICATIONS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206-04-2

DESCRIPTION AND OPERATION

Rear Disc Brake

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206-04-3

Service Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..206-04-3

Parking

Brake

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...206-04-3

DIAGNOSIS AND TESTING

Brake Calipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...206-04-4

Inspection

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206-04-4

REMOVAL AND INSTALLATION

Brake Caliper Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206-04-5

Brake Caliper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .206-04-5

Rear Brake Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...206-04-5

Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206-04-6

Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..206-04-7

Beam Axle Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . . ...206-04-7

DISASSEMBLY AND ASSEMBLY

Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206-04-8