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Brake caliper housing with integral parking brake on the rear axle. To ensure that the parking brake works perfectly, when a new brake caliper is fitted, and every time the brake pads are replaced the piston must be adjusted as described below: Removal: Release / unclip the handbrake cable Remove screw plug (a) – see Fig. 1 Slacken the hexagon socket screw (Fig. 2). Withdraw the piston until it stops moving. Installation: Screw in the hexagon socket screw in a clockwise direction (Figure 3) until the brake shoes touch the brake disc and the brake disc becomes difficult to turn. Then slacken the adjuster screw by one third to half of a turn (Brake disc will turn easily – see Fig. 4). Screw in and tighten screw plug (1) – Fig. 5. Attach brake cable and adjust it in accordance with the manufacturer’s instructions.

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Getting started 1. Apply the handbrake. 2. Place chocks under the front wheels and engage 1st gear. Remove the Brake Caliper 6. The brake caliper needs to be removed to allow the brake disc to be removed. Working under the car remove the clip securing the brake hose in place. 3. Loosen the rear wheel nuts using a 19mm wheel wrench with the car on the ground. 4. Jack up the car and support safely using axle stands or ramps. Preferably jack up both sides at the same time, as it makes it easier to balance the handbrake action at the end. This will free the hose and pipe. Carefully slip the pipe fitting out of the bracket. 7. Remove the caliper lower fixing bolt (16mm socket). 5. Remove the road wheel. 8. Remove the plastic cap over the upper fixing bolt. Remove the Brake Disc 11. Loosen the brake disc holding screw using a T-30 Torx bit. 9. Use a 6mm allan key to remove the upper fixing bolt. 12. Release the hand brake and remove the brake disc. If this proves difficult, it may be necessary loosen the brake adjuster. To do this, remove the rubber plug…. 10. The caliper will now be loose and can be carefully lifted away from the disc, taking care to route the brake pipe gently to avoid strain. Support the caliper from the suspension spring using string or ties. …and turn the adjuster with a screwdriver inserted through the hole. The disc has been removed here to show the teeth on the adjuster.

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WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer’s specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. 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 serious personal injury. WARNING: Always install new brake shoes or pads at both ends of an axle to reduce the possibility of brakes pulling vehicle to one side. Failure to follow this instruction may result in uneven braking and serious personal injury. NOTICE: Do not spill brake fluid onto painted or plastic surfaces or damage to surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. 1. Check the brake fluid level in the brake master cylinder reservoir. If required, remove the fluid until the brake master cylinder reservoir is half full. 2. Remove the wheel and tire. For additional information, refer to Section 204-04. 3. NOTICE: Do not allow the brake caliper to hang by the flexible brake hose or damage to the hose may occur. Remove the 2 brake caliper guide pin caps and bolts and position the caliper and brake pad assembly aside. Support the caliper using mechanic’s wire. Remove and discard the guide pin bushings. Inspect the guide pin threads for damage, install new guide pin(s) as necessary. 4. Remove the brake pads from the caliper. 5. Inspect the brake pads for wear or contamination and install new pads as necessary. For additional information, refer to General Procedures in Section 206-00. 6. Using a C-clamp and a worn brake pad, press the piston into the caliper. 7. Inspect the brake disc and resurface or install a new brake disc as necessary. For additional information, refer to General Procedures in Section 206-00. Installation 1. Clean, dry and inspect the brake caliper anchor plate. Apply equal amounts of the supplied yellow lubricant to the 4 brake pad contact points on the anchor plate as shown. 2. NOTICE: Do not apply lubricant to guide pin threads or incorrect tightening of the guide pins may result. Install new brake hardware as follows: Apply equal amounts of the supplied white lubricant to the inside of the guide pin bushings. Install the guide pin bushings into the caliper bores. Install the guide pins into the bushings. 3. Install the brake pads to the caliper. 4. Position the caliper onto the anchor plate and install the 2 brake caliper guide pin bolts. To install, tighten to 38 Nm (28 lb-ft). Clean and dry guide pin threads as necessary. 5. Fill the master cylinder with clean, specified brake fluid. 6. Install the wheel and tire. For additional information, refer to Section 204-04. 7. Apply the brake several times to verify correct brake operation.

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REMOVAL & INSTALLATION WHEEL BEARING Removal 1) Raise and support vehicle. Remove front wheels. Remove cotter pin, bearing lock nut cap and bearing lock nut (apply brakes when removing lock nut). Remove brake caliper. DO NOT disconnect brakeline. Secure caliper aside. 2) Remove disc brake rotor. Remove ABS speed sensor (if equipped). Loosen, but DO NOT remove, shock absorber lower mounting bolts. Remove cotter pin and castle nut from tie rod end. Using Puller (09628-62011), remove tie rod end from steering knuckle. 3) Remove nuts and bolt attaching lower ball joint to lower control arm. Using Puller (09950-20017), disconnect steering knuckle from axle shaft. See Fig. 1. Remove steering knuckle and axle hub as an assembly. Place steering knuckle in a vise. Remove dust deflector. 1) Raise vehicle, and place a wooden block with a height of 7.09-7.87″ (180.0-200.0 mm) under either front tire. Lower floor jack until about half vehicle load is on front struts. Place safety stands under vehicle. 2) Place front wheels in straight-ahead position, and block them. Use a rod to move control arm up and down. Check for vertical ball joint play. If ball joint is damaged or any vertical play is found, replace ball joint. See LOWER CONTROL ARM & BALL JOINT under REMOVAL & INSTALLATION.

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1. Loosen the strut tower nuts by at least five turns. See Fig. 4 . Loosen the wheel hub retaining nut. Raise and support vehicle. Remove front wheel, brake caliper and rotor. Remove ABS wheel speed sensor (if equipped). Remove tie rod end cotter pin and nut. Using Tie Rod End Separator (211-001), remove tie rod end. See Fig. 13 . 2. Remove lower control arm nut and pinch bolt. See Fig. 15 . Separate lower control arm from steering knuckle. Remove wheel hub retaining nut. Using a suitable puller, separate wheel hub from halfshaft. See Fig. 6 . Remove strut assembly-to-steering knuckle bolt. See Fig. 3 . Remove steering knuckle. Disassembly & Reassembly 1. Using Bearing Pulling Attachment (205-D064), press wheel hub from wheel knuckle. See Fig. 7 . Remove retainer ring from wheel knuckle. See Fig. 8 . Using a suitable drift, remove front wheel bearing from wheel knuckle. See Fig. 9 . CAUTION: Avoid any impact on the wheel speed sensor ring. Make sure the wheel speed sensor ring is clean. Avoid any contact between the wheel speed sensor ring and a magnetic surface. Make sure the wheel bearing is installed into the wheel knuckle with the wheel speed sensor ring, colored black, at the wheel speed sensor end of the wheel knuckle. 2. To reassemble, reverse disassembly procedure.