1996 Ford EXPLORER

Submodel: | Engine Type: V6 | Liters: 4.0

Fuel Delivery: FI | Fuel: GAS

Subarticles

Disassembly
Assembly

Section 06-03: Brake, Front Disc 1996 Aerostar/Ranger/Explorer Workshop Manual

DISASSEMBLY AND ASSEMBLY Procedure revision date: 05/18/2000

Caliper, Ranger and Explorer

Disassembly
SPECIAL SERVICE TOOL(S) REQUIRED

Description Tool Number

Piston Dust Seal Replacer T92P-2588-AH
Driver Handle T80T-4000-W

1. Remove the disc brake caliper (2B120) from the vehicle. Refer to the procedure in this section.

2. CAUTION: Use care to retain as much of the original caliper slide pin grease as possible.
Remove the caliper slide pins and caliper slide pin dust boots from the front disc brake caliper anchor plate.

3. NOTE: Because there are two caliper pistons, it is desired to have both pistons nearly expelled before the seal is broken. Therefore, the dimensions of the
wood block used to assist removal are important. A block 38 x 38 x 150mm (1.5 x 1.5 x 6 inches) is recommended.
Place a wood block in the disc brake caliper jaws to avoid damage to the disc brake caliper pistons when they are forced out of the disc brake caliper bores.

4. WARNING: TO AVOID DAMAGE OR INJURY, USE ONLY ENOUGH AIR PRESSURE TO EXPEL THE PISTON. DO NOT ATTEMPT TO CATCH THE CALIPER
PISTON AS IT IS FORCED OUT OF THE DISC BRAKE CALIPER.
Using a rubber nosed air nozzle at the brake fluid inlet port, apply low pressure air to force the disc brake caliper pistons out of the disc brake caliper bores.

5. To encourage the removal of a reluctant caliper piston, tap gently around it. If a caliper piston cannot be removed from the disc brake caliper, replace the disc brake caliper.

6. Using a suitable tool, pry the caliper piston dust boots out of the disc brake caliper bores. Discard the caliper piston dust boots.

7. CAUTION: To avoid damage to the bores or seal seats, use only a non-metallic tool to remove the piston seals.
Remove and discard the disc brake caliper piston seals from the caliper bores.

Item Part Number Description

1 2208 Bleeder Screw
2 2B120 Disc Brake Caliper Housing
3 2B292 Front Disc Brake Caliper Anchor Plate
 4 2001 Brake Shoe and Lining, Outboard
5 2196 Caliper Piston
6 2B115 Piston Seal
7 2207 Dust Boot
8 2001 Brake Shoe and Lining, Inboard
A - Tighten to 17-24 Nm (13-18 Lb-Ft)

Assembly

1. Clean and inspect the disc brake caliper bores for scoring, rust, pitting or other damage. Do not hone a worn or damaged caliper bore. A new disc brake caliper must be
used.

2. Clean and inspect the caliper pistons for cracks or other damage. Do not attempt to repair a worn or damaged caliper piston. A new one must be installed.

3. Clean and inspect the caliper pin bolt bushings. Replace if worn or damaged.

4. CAUTION: Do not use anything but clean brake fluid to lubricate the caliper pistons, seals and caliper bores. Use of any other lubricant may cause
premature failure of brake components.
Lubricate the caliper bores, new piston seals and the caliper pistons with clean Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AA or equivalent DOT 3 fluid
meeting Ford specification ESA-M6C25-A.

5. Install the new piston seals into the caliper bore seal grooves. Make sure the seals are not twisted and are fully seated.

6. Install the caliper pistons into the caliper bores past the piston seals. Use a rocking, twisting motion and use care not to distort the piston seals.

7. After the caliper pistons are past the piston seals, press the caliper pistons about 2/3 into the caliper bores.

8. CAUTION: Effective operation of the disc brake caliper is directly affected by the condition of the caliper piston dust boots. Use care not to dislodge or
damage them.
Install the new dust boots on the caliper pistons.

9. Using Piston Dust Seal Replacer T92P-2588-AH and Driver Handle T80T-4000-W seat the dust boots into the caliper bores. Make sure the dust boots are fully seated into
the caliper piston grooves and caliper bore grooves. After installation, the dust boots should not extend beyond the face of the caliper piston.

10. After installing the dust boots, press the caliper pistons to the bottom of the caliper bores.

11. CAUTION: For Ranger and Explorer disc brakes, the caliper slide pins are covered by a flexible boot and are intended to be lubed for life. At time of
publication, there was no approved material or procedure for re-lubing the caliper slide pins. For routine service such as brake pad replacement, the
slide pins, grease and boots should be reused as are, if not damaged. If damaged, new pins (with new boots and grease included) must be installed.
CAUTION: Do not use petroleum or mineral based service greases (such as Ford Disc Brake Caliper Slide Grease D7AZ-19590-A or equivalent) for this
application. Such greases will cause rapid deterioration of the slide pin boots. Service life of the disc brakes could be reduced as a result.
Install the caliper slide pin dust boots into the disc brake caliper anchor plate. Make sure the boots are fully seated in the grooves.

12. Install the caliper slide pins into the caliper slide pin boots. Make sure the caliper slide pin boots are seated in the grooves in the caliper slide pins.

13. Expel the air from the caliper slide pin boots and make sure the caliper slide pins are fully coated with lubricant.

14. Install the disc brake caliper on the front disc brake caliper anchor plate. Refer to the procedure in this section.