Ford Explorer: Front Disc Brake / Removal and Installation - Brake Caliper

Removal

  WARNING: Service actions on vehicles equipped with electronic brake booster and electronic parking brakes may cause unexpected brake application, which could result in injury to hands or fingers. Put the brake system into service mode prior to servicing or removing any brake components. Failure to follow this instruction may result in serious personal injury.

NOTICE: Make sure that all openings are sealed.

NOTICE: If the fluid is spilled on the paintwork, the affected area must be immediately washed down with cold water.

NOTE: Removal steps in this procedure may contain installation details.

1. Activate the brake service mode.
   Refer to: Brake Service Mode Activation and Deactivation (206-00 Brake System - General Information, General Procedures).
   

1. Remove the wheel and tire.
   Refer to: Wheel and Tire (204-04A Wheels and Tires, Removal and Installation).
   

1. NOTE: Make sure all openings are sealed.

   Remove the bolt and disconnect the brake hose. Discard the washers.
   Torque: 26 lb.ft (35 Nm)

Vehicles without adhesive on outboard brake pad insulator

1. Remove the bolts and the brake caliper.
   Torque:
      M8 ::   20 lb.ft (27 Nm)
      M10 ::   34 lb.ft (46 Nm)

Vehicles with adhesive on outboard brake pad insulator

NOTICE: Brake pads with adhesive on the insulator are one-time use only. When the brake pads are separated from the brake caliper, new brake pads must be installed to prevent brake noise and shudder.

1. Remove the brake caliper mounting bolts.
   Torque:
      M8 ::   20 lb.ft (27 Nm)
      M10 ::   34 lb.ft (46 Nm)

1. NOTICE: Brake pads with adhesive on the insulator are one-time use only. When the brake pads are separated from the brake caliper, new brake pads must be installed to prevent brake noise and shudder.

   1. Separate the outboard brake pad from the brake caliper.
      
   2. Remove the brake caliper.
      

Installation

Vehicles with adhesive on outboard brake pad insulator

1. Install the new brake pads.
   Refer to: Brake Pads (206-03 Front Disc Brake, Removal and Installation).
   

All vehicles

NOTICE: Make sure that the brake hose is not twisted when installing the brake caliper or damage to the brake flexible hose may occur.

1. To install, reverse the removal procedure.
   

1. Deactivate the brake service mode.
   Refer to: Brake Service Mode Activation and Deactivation (206-00 Brake System - General Information, General Procedures).
   

1. Bleed the brake system.
   Refer to: Brake System Pressure Bleeding (206-00 Brake System - General Information, General Procedures).