Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in personal injury. CAUTION: Do not spill brake fluid onto painted or plastic surfaces. If spilled, wipe up immediately before damage to the plastic or painted surfaces occurs. 1. Remove the wheel and tire assembly. For additional information, refer to Section 204-00. 2. Remove the parts in the order indicated in the following illustration and table. To remove individual parts, only carry out the listed steps: 3. To install, reverse the removal procedure. 4. If the hydraulic system was opened, bleed the brake system. For additional information, refer to Brake System Bleeding in this section. Item 2: Brake Caliper Removal Note 1. CAUTION: Do not allow the brake caliper to hang by the flexible brake hose. Support the caliper to the vehicle. Item 11: Brake Disc Removal Note 1. If removing the brake disc, only remove the caliper bracket bolts and position the caliper and bracket aside. Item 10: Spindle Nut Installation Note 1. Tighten the spindle nut to the specified torque. Rotate the hub counter-clockwise 5 rotations and then recheck the torque. Item 3: Brake Disc Pads Installation Note 1. CAUTION: Install a new lining if worn to or past the specified thickness above the metal backing plate or if the pad is damaged. Install new pads in complete axle sets. If replacing the brake pads, use a suitable suction device, remove the brake fluid in the master cylinder reservoir until it is half filled. 2. If replacing the brake pads, use a suitable tool to push the brake caliper pistons into the caliper bore. 3. One brake disc pad kit contains the pads required for both the RH and LH side. Item 1: Caliper Bolt Installation Note 1. Tighten the bottom caliper bolt and then the top caliper bolt. Item 11: Brake Disc Inspection Note 1. NOTE: If machining is necessary use a hub-mount brake lathe to machine the front brake disc. For additional information, refer to section Section 100-04. Measure the front brake disc, and resurface as necessary. Install a new front brake disc if beyond specification.

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Some 2004/2005 F-150 vehicles built before 11/29/2004 may exhibit front brake roughness and or shudder while braking. ACTION Service the rack and pinion, rotors, and caliper assemblies as needed, based on vehicle build date and current part levels installed on the vehicle. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Vehicles built prior to 8/20/2003 require the replacement of the rack and pinion assembly if it has not been replaced. Refer to Workshop Manual, Section 206-03 and 211-02. 2. Determine if the vehicle has the old or new level rotors (Figure 1).WHEN REPLACING THE ROTORS ON 4X2 UNITS, A NEW SPINDLE NUT IS REQUIRED. b. If new level (47 fin) rotors are present, perform one (1) of the following: (1) (2) If rotors are within minimum thickness specifications, machine the rotors using the Rotunda on vehicle brake lathe and the Rotunda adapter kit 201-R0093. Refer to the Workshop Manual, Section 206-00 for the correct on-vehicle brake lathe procedure. If rotors are beyond machinable thickness, the front rotors must be replaced. 3. Install new service fix calipers. NOTE REPLACE CALIPERS WITH NEW SERVICE FIX CALIPER ASSEMBLIES BY REMOVING THE CALIPERS AT THE KNUCKLES. THE SERVICE REPLACEMENT CALIPERS WILL BE PRE-ASSEMBLED WITH ANCHOR, SPRINGS, AND PADS. THE CALIPERS SHOULD BE INSTALLED AS A UNIT WITHOUT DISASSEMBLY.

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NOTE: Minimum thickness for replacing the brake pads = 3.0 mm . Remove the securing spring and locating pins Remove: the securing spring (3) carefully so that it does not deform the protective caps (1) from the two locating pins (2) the locating pins, use hex socket 7 mm . Remove the brake caliper and brake pads Remove: the brake caliper from the holder the brake pads. Hang brake caliper from a steel wire from the front spring so as not to damage brake hose. NOTE: Do not depress the brake pedal while the brake pads are removed. Clean and check brake caliper and dust cover Brake Pads, Rear, Replacing Removal NOTE: Minimum thickness for replacing the brake pads = 3.0 mm . Remove retaining springs and locating pins for brake pads Remove:

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CAUTION: Use of incompatible bearing lubricant could result in premature lubricant breakdown. The recommended wheel bearing lubricant is the lithium-base grease High Temperature 4×4 Front Axle and Wheel Bearing Grease E8TZ-19590-A or equivalent meeting Ford specification ESA-M1C198-A. Sodium-base grease is not compatible with lithium-base grease and should not be intermixed. Therefore, before lubricating front or rear wheel bearings (1225), thoroughly clean all old grease from the bearing and front disc brake hub and rotor (1102). If bearing adjustment does not eliminate looseness or rough and noisy operation, clean and inspect the front disc brake hub and rotor and bearings. If bearing cups or the cone and roller assemblies are worn or damaged, replace. Disassembly 1. Raise vehicle and install safety stands. 2. Remove the wheel and tire. Refer to Section 04-04 in the Body, Chassis Manual. 3. Remove the locking hubs. 4. CAUTION: Do not let the disc brake caliper (2B120) hang only by the hose, or damage might occur to the hose or disc brake caliper. Remove the disc brake caliper. Refer to Section 06-03 in the Body, Chassis manual. Securely wire the disc brake caliper to the frame. 5. For vehicles equipped with automatic locking hubs, remove C-ring or snap ring and three-piece thrust washers (spacers). Remove the cam assembly and wheel bearing nut retaining key. Remove wheel bearing retainer (nut) using Hub Nut Wrench T95T-1197-B. Repack the wheel bearings with the specified lubricant (grease). For vehicles with manual locking hubs, remove snap ring, three-piece thrust washers (spacers), the outer lock nut, lockwasher, and inner lock nut using Spanner Locknut Wrench D85T- 1197-A or equivalent. 6. Remove the front disc brake hub and rotor. The front outer wheel bearing will slide out as the hub is removed. 7. Remove the retaining nuts of the front wheel spindle (3105). Carefully remove the front wheel spindle from the knuckle studs and halfshaft (3A329). If necessary, lightly tap the end of the spindle with a rawhide hammer to remove. 8. Clean old grease from the needle bearings and the bore seal of the front wheel spindle. To replace spindle bearing or inner seal, refer to Section 05-03A or Section 05-03B. 9. Clean any old grease or dirt from these parts and replace if signs of excessive wear are noted. Assembly 1. Using High-Temperature 4×4 Front Axle and Wheel Bearing Grease E8TZ-19590-A or equivalent meeting Ford specification ESA-M1C198-A, thoroughly lubricate the needle bearing and coat the front wheel spindles or face that mates with the seals of the front wheel spindle. 2. Assemble the front wheel spindle over the halfshaft onto the knuckle studs. Tighten the retaining nuts to 68-81 Nm (50-60 lb-ft). 3. Remove the front inner wheel bearing, wheel hub grease seal (1190) from the front disc brake hub and rotor using Bearing Cup Puller T77F-1102-A and Impact Slide Hammer T50T-100-A. Inspect bearings and replace as necessary. 4. Inspect the bearing cups for pits or cracks. If necessary, remove with a drift. If new cups are installed, install new cones and rollers. 5. Lubricate the bearings with High Temperature 4×4 Front Axle and Wheel Bearing Grease E8TZ-19590-A or equivalent meeting Ford Specification ESA-M1C198-A. Clean all old grease from the front disc brake hub and rotor. Pack the cones and rollers. If a bearing packer is not available, work as much lubricant as possible between the rollers and the cages. 6. Position the front inner wheel bearing in the inner cup and install the new wheel hub grease seal using a hammer, Driver Handle T80T-4000-W and the proper seal installer.

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When a new brake master cylinder (2140) has been installed, or the brake system emptied or partially emptied, fluid may not flow from the bleeder screws during normal bleeding. It may be necessary to prime the system using the following procedure: 1. Use a tubing wrench to remove the brake lines from the master cylinder. 2. Install short brake lines in the brake master cylinder and position them so that they point back into the reservoir, and the ends of the pipes are submerged in brake fluid. 3. Fill the reservoir with new Ford High Performance DOT-3 Brake Fluid C6AZ-19542-AA or DOT-3 equivalent meeting Ford specification ESA-M6C25-A. 4. Cover the reservoir with a clean shop towel. 5. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water. Pump the brakes until clear, bubble-free fluid comes out of both brake lines. 6. Remove the short brake lines and reinstall the ones from the vehicle. 7. Bleed each brake line at the brake master cylinder using the following procedure: a. Have an assistant pump the brake pedal 10 times and then hold firm pressure on the pedal. b. Loosen the front brake line fitting with a tubing wrench until a stream of brake fluid comes out. Have your assistant maintain pressure on the brake pedal until the brake line fitting is tightened again. c. Repeat this operation until clear, bubble-free fluid comes out from around the tubing fitting. d. Repeat this bleeding operation at the rear brake line fitting. 8. If any of the brake lines or calipers have been removed, it may be helpful to prime the system by gravity bleeding it. This should be done after the brake master cylinder is primed and bled. To prime the brake system: a. Fill the brake master cylinder reservoir (2K478) with new Ford High Performance DOT-3 Brake Fluid C6AZ-19542-AA or equivalent meeting Ford specification ESA-M6C25-A. b. Loosen both rear caliper bleeder screws and leave them open until clear brake fluid flows out. Be sure to check the reservoir fluid level often and not let it run dry. c. Tighten the bleeder screws. d. One at a time, loosen the front caliper bleeder screws. Leave the bleeder screws open until