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

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Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. Avoid breathing dust particles. Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Inspection 1. Raise the rear of the vehicle, and support it with safety stands in the proper locations. 2. Remove the rear wheels. 3. Check the thickness (A) of the inner pad (B) and the outer pad (C). Do not include the thickness of the backing plate. 4. If any of the brake pad thickness is less than the service limit, replace the rear brake pads as a set. 5. Clean the mating surfaces between the brake disc and the inside of the wheel, then install the rear wheels. Replacement 1. Remove some brake fluid from the master cylinder. 2. Raise the rear of the vehicle, and support it with safety stands in the proper locations. 3. Remove the rear wheels. 4. Remove the brake hose mounting bolt (A). 5. Remove the flange bolts (B) while holding respective caliper pin (C) with a wrench. Be careful not to damage the pin boot, and remove the caliper (D). Check the hose, the pin boots, and the parking brake cable boots for damage and deterioration. NOTE: Do not twist the brake hose and the parking brake cable to prevent damage. 6. Remove the pad shim (A) and the brake pads (B). 7. Remove the pad retainers (A). 8. Clean the caliper bracket (B) thoroughly; remove any rust, and check for grooves and cracks. Verify that the caliper pins (C) move in and out smoothly. Clean and lube if needed. 9. Inspect the brake disc, and check for damage and cracks. 10. Apply a thin coat of M-77 assembly paste (P/N 08798-9010) to the retainer mating surface of the caliper bracket (indicated by the arrows and shaded area). 11. Install the pad retainers. Wipe excess assembly paste off the retainers. Keep the assembly paste off the brake disc and the brake pads.

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Some vehicles may exhibit a grabbing condition from the rear brakes during the first few brake applications. The condition only occurs after the vehicle has been parked for several hours. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE To service, reduce/minimize moisture intrusion into the rear drum brake assemblies by applying Motorcraft® Silicone Gasket and Sealant to the brake backing plate. 1. Place vehicle on hoist and remove the rear wheels. 2. Remove the rear brake drums and replace the rear linings. Refer to Workshop Manual (WSM), Section 206-02. WARNING Do not breathe dust or use compressed air to blow dust from storage containers or friction components. Remove dust using government-approved techniques. Friction component dust may be a cancer and lung disease hazard. Exposure to potentially hazardous components may occur if dusts are created during repair of friction components, such as brake pads and clutch discs. Exposure may also cause irritation to skin, eyes and respiratory tract, and may cause allergic reactions and/or may lead to other chronic health effects. If irritation persists, seek medical attention or advice. Failure to follow these instructions may result in serious personal injury. 3. Inspect the rear brake assemblies for damaged, missing and/or improperly seated adjuster plug or parking brake cable. 4. Inspect and clean the lining contact area of the brake drum; machine if necessary. 5. Reinstall the rear brake drums and adjust the lining to drum clearance per WSM, Section 206-02. 6. Thoroughly clean the backside of the rear drum brake backing plate to promote proper adhesion of sealant. 7. Apply Motorcraft(R) Silicone Gasket and Sealant to the backside of the rear drum brake backing plate at the following inter[ace areas (Figure 1): ^ Axle Flange ^ Wheel Cylinder ^ Parking Brake Cable ^ Hold Down Pins NOTE AVOID GETTING SEALANT ON THE BRAKE BLEED SCREW AND BRAKE TUBE NUT. 8. Reinstall the rear wheels and torque lug nuts per Workshop Manual, Section 204-04.

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CAUTION: Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. Avoid breathing dust particles Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. 1. Loosen the front wheel nuts slightly. Raise the front of the vehicle, and make sure it is securely supported. Remove the front wheels. 2. Remove the brake hose mounting bolt (A) from the knuckle. 3. Hold the caliper pin with a wrench, being careful not to damage the pin boot. Remove the caliper bolt (B) with another wrench. 4. Pivot the caliper (C) up out of the way. Check the hoses and pin boots for damage and deterioration. 5. Remove the pad shims (A), pad retainers (B), and pads (C). The ‘99-01 models have two pairs of pad shims. The ‘02 model has one pair of the pad shims. 6. Using vernier calipers, measure the thickness of each brake pad lining. The measurement does not include pad backing plate (A) thickness. 7. If the brake pad thickness is less than the service limit, replace the front pads as a set. 8. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks. 9. Check the brake disc for damage and cracks. Install the pad retainers (A). Apply Molykote M77 grease or Daikalub 528D grease to both sides of the pad shims (A) and the back of the pads (B). Wipe excess grease off the shim. Contaminated brake discs or pads reduce stopping ability. Keep grease off the discs and pads. 12. Install the brake pads and pad shims correctly. The ‘99-01 models have two pairs of the pad shims. The ‘02 model has one pair of the pad shims. Install the pad with the wear indicator (C) on the inside. NOTE: Check the brake fluid level, the brake fluid may overflow the reservoir if too full.

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Frequent inhalation of brake pad dust, regardless of material composition, could be hazardous to your health. Avoid breathing dust particles. Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Inspection Raise the rear of the vehicle, and support it with safety stands in the proper locations. Remove the rear wheels. Check the thickness (A) of the inner pad (B) and the outer pad (C). Do not include the thickness of the backing plate. If any part of the brake pad thickness is less than the service limit, replace the rear brake pads as a set. Clean the mating surfaces between the brake disc and the inside of the wheel, then install the rear wheels. Replacement Remove some brake fluid from the master cylinder. Raise the rear of the vehicle, and support it with safety stands in the proper locations. Remove the rear wheels. Remove the brake hose mounting bolt (A). Remove the flange bolts (B) while holding respective caliper pin (C) with a wrench. Be careful not to damage the pin boot, and remove the caliper (D). Check the hose and pin boots for damage and deterioration. NOTE: Do not twist the brake hose and the parking brake cable to prevent damage. Remove the pad shims (A) and the brake pads (B).

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Never use an air hose or dry brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner to avoid breathing brake dust . 1. Loosen the front wheel nuts slightly, then raise the vehicle and support if on safety stands. 2. Remove the caliper bolt, and pivot the caliper up out of the way. NOTE: Check the hoses and pin boots for damage or deterioration. 3. Remove the pad shim, pad retainers and pads. 4. Using vernier calipers, measure the thickness of each brake pad lining. The measurement does not include pad backing plate thickness. Brake Pad Thickness: Standard: Type R Model: 10.5 – 11.5 mm 10.41 – 0.45 inch) All except Type R Model: 9.5 – 10.5 mm (0.37 – 0.41 inch) Service Limit: 1.6 mm 10.06 inch) 5. If the brake pad thickness is less than the service limit, replace the front pads as a set. 6. Clean the caliper thoroughly; remove any rust, and check for grooves and cracks.