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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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Fig. 1: View Of Rear Wheel Drive Shaft Spindle Nut 1. Remove the rear brake drum. Refer to Brake Drum Replacement in Drum Brakes. 2. On vehicles with all-wheel drive, remove the wheel drive shaft spindle nut. Fig. 2: Disconnecting/Connecting Wheel Speed Sensor Electrical Connector 3. Disconnect the wheel speed sensor electrical connector, if equipped. IMPORTANT: Do not damage the wheel drive shaft joint seal. Fig. 3: View Of Wheel Bearing/Hub & Mounting Bolts 4. Support the wheel drive shaft with heavy mechanic’s wire, or equivalent. 5. Remove the wheel bearing/hub mounting bolts. 6. Remove the wheel bearing/hub assembly from the suspension knuckle.

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Exploded View Of Knuckle/Hub Assembly Removing Brake Caliper Removing Wheel Sensor From Knuckle Removing Spindle Nut Locating Brake Disc Screws Removing Cotter Pin From Tie-Rod End Ball Joint 2003 Honda Pilot LX 2003-04 SUSPENSION Front – Pilot Remove the brake disc from the hub. Inspect the front hub for damage and cracks. Remove the cotter pin (A) from the tie-rod end ball joint, then loosen the nut (B). See Fig. 15 . Disconnect the tie-rod ball joint from the knuckle using the ball joint remover.

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Exploded View REAR DRUM BRAKE TYPE: ‘99-01 models Exploded View REAR DISC BRAKE TYPE: ‘02-04 models REAR DRUM BRAKE TYPE: ‘99-01 models 1. Raise the rear of the vehicle, and support it with safety stands in the proper locations. 2. Remove the wheel nuts (A) and rear wheel (B). 3. Press the parking brake pedal. 4. Remove the hub cap (C). 5. Raise the locking tab on the spindle nut (D), then remove the nut. 6. Release the parking brake pedal.

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Removal (Except Odyssey & S2000) 1. Loosen lug nuts with vehicle weight on tires. Pry lock tab away from spindle nut, and loosen nut. Raise and support vehicle. Remove lug nuts and spindle nut. Remove wheel assembly. Remove brake hose mounting bolts, caliper assembly, and support aside. DO NOT put weight on flexible brake line. 2. Remove brake disc retaining screws. Install two 8 x 1.25-mm bolts in brake disc, and tighten bolts to force brake disc from hub. Alternate tightening of bolts to prevent brake disc from binding on hub. Disconnect ABS wheel sensor (if equipped) from steering knuckle and set aside. DO NOT disconnect sensor connector. Remove cotter pin and nut from tie rod end. 3. On all models except Prelude with Active Torque Transfer System (ATTS), use Ball Joint Remover (07MAC-SL00200). Separate tie rod ball joint and lift tie rod end out of knuckle. See Fig. 2 , Fig. 3 and
Fig. 5 . On Prelude with Active Torque Transfer System (ATTS), remove cotter pin and radius rod ball joint nut. Using ball joint separator, separate radius rod ball joint from radius rod. On all models, remove cotter pin from lower control arm ball joint, and nut. Using ball joint remover, separate lower ball joint from control arm. 4. Remove cotter pin and upper ball joint stud nut. Using ball joint remover, separate ball joint from steering knuckle. Remove steering hub/knuckle assembly from axle shaft.