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

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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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90 Nm + 45 ° ( 1 / 8 ) additional turn. loosening and tightening Remove any paint residue and/or corrosion in the threads of outer joint before screwing on nut. 3 – Phillips-head screw 4 – Brake disc Notes for repairing 5 – Brake caliper Do not remove brake hose when working on front wheel suspension Hang with wire or similar means Replace brake pads 6 – Metal countersunk screw 7 – Wheel hub Pressing out Pressing in Remove bearing inner race 8 – Rotor for speed sensor Only on vehicles with ABS Front brakes – brake caliper Girling, servicing Brake pads, removing and installing 9 – Hex bolt, 10 Nm 10 – Cover plate 11 – Securing ring Check for proper seating 12 – Wheel bearing Pressing out Replace, destroyed during ejection Pressing in 13 – Self-locking hex nut, 35 Nm 14 – Wheel bearing housing 15 – Ribbed bolt, 125 Nm 16 – Drive axle Removing and installing Servicing 17 – Multipoint socket head bolt, 45 Nm 18 – Hex bolt Camber setting Drive axle with triple rotor joint, removing and installing Drive axle, servicing Camber of front wheels, adjusting Mark installation position before loosening 19 – Hex bolt 20 – Bracket 21 – Stop 22 – Self-locking hex nut, 60 Nm unbolt and bolt in 23 – Suspension strut Disassembling and assembling 24 – Self-locking hex nut, 95 Nm 25 – Tie rod Removing and installing Front suspension strut – Basic/Plus suspensions, servicing Tie rod – power steering gear, TRW and ZF, removing and installing

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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: 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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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02. 2. Remove the wheel and tire assembly. For additional information, refer to Section 204-04. 3. CAUTION: Do not reuse the torque prevailing design hub nut and washer assembly. Remove and discard the hub nut and washer assembly. 4. CAUTION: Do not allow the disc brake caliper to hang suspended from the brake hose. Provide a suitable support. Remove the caliper support bracket bolts, then position the caliper and support bracket aside. 5. Remove the brake disc. 6. CAUTION: Do not use a hammer to separate the outboard front wheel halfshaft joint from the wheel hub. Damage to the outboard CV joint stub shaft threads and internal CV joint components may result. Using the special tool, separate the outboard front wheel halfshaft joint from the wheel hub. Remove the special tool. 7. Disconnect the front anti-lock brake sensor (ABS) wire from the vehicle frame. 1. Disconnect the ABS electrical connector. 2. Unclip the front ABS wire from the vehicle frame. 8. Using a suitable jack, support the front suspension lower arm. 9. CAUTION: Secure the front axle shaft to prevent it from overextending. Failure to do so can cause damage to the front axle shaft. Support the front axle shaft with wire. 10. Remove the tie-rod end castellated nut. 1. Remove and discard the cotter pin. 2. Remove and discard the castellated nut. 11. CAUTION: Do not use a hammer to separate the tie-rod from the wheel knuckle or damage to the wheel knuckle will result. CAUTION: Do not damage the tie-rod boot when installing the special tool. Using the special tool, separate the tie-rod end from the front wheel knuckle. 12. Remove the lower ball joint castellated nut.