Ford Falcon. Manual — part 63

206-03-1

Front Disk Brake

206-03-1

SECTION : 206-03 Front Disk Brake

VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS

PAGE

SPECIFICATIONS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206-03-2

DESCRIPTION AND OPERATION

Front Disc Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206-03-3

Disc Pad Running Clearance . . . . . . . . . . . . . . . . . . . . . . . ...206-03-4

Wear

Adjustment

. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..206-03-4

Rotor

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206-03-4

DIAGNOSIS AND TESTING

Front Disc Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206-03-5

REMOVAL AND INSTALLATION

Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206-03-6

Front Brake Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...206-03-7

Brake Caliper Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206-03-7

Brake Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..206-03-8

DISASSEMBLY AND ASSEMBLY

Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206-03-9

206-03-2

Front Disk Brake

206-03-2

SPECIFICATIONS

General Specifications

Description

Specification

Minimum brake disc

26.0

thickness(discard

thickness)
Fluid
Brake fluid

ESZ-M6C55-A

Lubricant
High melting point grease Dow Corning 44/Niglube

Rx2

Pad
Material

JBUF85FF

Lining wear limit

1.0mm

Torque Specifications

Description

Nm

Brake hose bolts

30

Disc brake caliper bolts

115

Brake hose banjo bolt

12-14

Caliper body bolt

98-132

G96750 en

206-03-3

Front Disk Brake

206-03-3

DESCRIPTION AND OPERATION

Front Disc Brake

Front Disc Brake Components

hydraulic seal between the piston and the cylinder

Item

Description

wall.

1

Front Disc Caliper Assembly

The top of the piston is machined to accept a sealing

2

Front Wheel Knuckle

dust boot. The outside diameter of the boot is

3

Brake Line Bracket

captured by a recess in the top of the cylinder bore

and the piston. The inside diameter of the boot fits

4

Caliper Retaining Bolt x 2

into the groove which is machined in the piston. The

5

ABS Sensor and Elec. Cable

piston is precision ground and chrome plated steel,

6

ABS Sensor Retaining Bolt

giving it a very hard and durable surface. The use of

7

Wheel Hub and Tone Wheel

abrasives or any attempt to re-machine the piston will

destroy the required surface finish.

8

Brake Disc Rotor

The sliding caliper feature automatically compensates

9

Front Spinle Nut

for lining wear. The abutment bracket is rigidly fixed to

10

Front Hub Cap Seal

the steering knuckle while the housing slides within

The dual piston hydraulic disc brake caliper is

the abutment bracket by means of two guide pins

constructed from a single casting which contains two

bolted to the housing.

piston bores in the inboard section of the casting.

Each caliper contains two pad assemblies. They are

(Inboard refers to the side of the casting which is

constructed of a stamped metal shoe with the lining

nearest the centreline of the vehicle when the caliper

integrally moulded to the shoe.

is mounted.)

When the brake pedal is applied, brake fluid is

The fluid inlet hole and bleeder valve hole are

displaced into the cylinders moving the pistons

machined into the inboard section of the caliper and

outward. This action forces the inner pad and lining

connect directly to the piston bores. Each cylinder

assembly against the rotor. The resultant reaction

contains a piston and seal.

forces the caliper housing and outboard pad assembly

The seal has a square section, and is located in a

inward against the rotor. The resultant forces of the

groove which is machined in the cylinder bore. It fits

pads on the rotor are equal. Braking torque is

around the outside diameter of the piston to provide a transferred from the outer brake pad abutments

G96751 en

206-03-4

Front Disk Brake

206-03-4

DESCRIPTION AND OPERATION (Continued)

through the caliper housing into the abutment bracket.

Guide Pin Adjustments

Braking torque from the inner brake shoe is taken

directly into the abutment bracket.
When the brake pedal is released the seal retracts the

piston into the cylinder and the caliper housing slides

outward releasing the brake.

Disc Pad Running Clearance

Piston Adjustment

Brakes Applied

Item

Description

1

Pad Abutment Bracket

2

Guided pin and boot assembly

3

Guide pin bolt

4

Piston

5

Piston dust boot

6

Pad abutment shim

7

Pads

Item

Description

The figure above shows the guide pin installation.

1

Piston Seal Distorted

Running clearance - the caliper head moves back and

forth on low friction guide pins. These guide pins and

2

Caliper Housing

intended to accommodate disc runout and bearing

3

Piston

float. If friction in the guide pin slide is high, instead of

the caliper head sliding back and forth, the disc will

Brakes Released

knock the piston into the head, causing a spongy

pedal on subsequent applications.

Wear Adjustment

Pad wear is taken up during brake application as

follows:

by the piston sliding past the seal to a new

position.
by movement of the caliper head on the slide pin.

Rotor

The cast iron disc is of the ventilated rotor-type and is

separated from the front hub.

Item

Description

1

Piston Seal Relaxed

2

Piston

3

Caliper Housing

The figures above show what happens to the pistons

and the seals during usage. The piston seals perform

the self-adjusting action. When the pistons are

pushed out by hydraulic pressure the piston seals

distort. When the hydraulic pressure is relieved the

seals relax and drag the pistons in, creating a disc to

pad running clearance.

G96751 en