Front Brakes - Popping or Clunking Noise
9235ford02Article No.
92-14-7
07/01/92
^ BRAKES - FRONT DISC - "POPPING" OR "CLUNKING" SOUND DURING BRAKING
^ NOISE - "POPPING" OR "CLUNKING" SOUND WHEN BRAKING
^ VIBRATION THROUGH FLOOR BOARD WHEN BRAKING
LIGHT TRUCK:
1989-90 BRONCO II
1989-92 AEROSTAR, RANGER
1991-92 EXPLORER
See TSB # 93-20-11 for additional information.
ISSUE:
A "popping" or "clunking" noise and a floor board vibration may occur during braking. The noise and/or vibration may be caused by the front brake caliper suddenly springing away from the caliper abutment and returning.
ACTION:
Check and adjust the brake pads and caliper knuckle clearance by using the following service procedure.
1. Road test to confirm that the "popping" or "clunking" noise occurs only during braking at the initial part of the stop.
2. Raise the front of the vehicle.
a. Remove the front wheels.
b. Remove the pins from the caliper.
3. While holding the caliper in place against the bottom pin rails, Figure 1, measure the clearance between the caliper and the top pin rails.
NOTE:
THE CLEARANCE SHOULD BE A MINIMUM OF .015" (.381 MM).
a. If the caliper clearance is less than .015" (.381 mm) on either caliper, replace the caliper and repeat the measurements.
b. If the caliper clearance is less than .015" (.381 mm) on both calipers, replace both calipers and recheck clearance.
c. If the caliper clearance is still less than .015" (.381 mm) on both calipers, replace both spindles (4X2) or knuckles (4X4) and recheck clearance.
NOTE:
CHECK THE CLEARANCE OF THE NEW KNUCKLE BEFORE INSTALLATION.
4. After measuring the caliper/knuckle for proper clearance, remove both calipers and brake pad assemblies. Refer to the appropriate Light Truck Service Manual, Section 06-03, for the removal procedure.
5. Replace the caliper piston (FOTZ-2196-A). Refer to the appropriate Light Truck Service Manual, Section 06-03, for the replacement procedure.
6. Install the new lining kit (FO9Z-2001-A).
a. Check the side and end clearances with a feeler gauge.
b. Refer to Figure 2 for clearance dimensions.
7. If the lining clearance is not to the required dimensions, file the shoe tab. Remove equal amounts from both sides and ends, Figure 3.
WARNING:
USE SAFETY GLASSES WHEN FILING THE BACKING PLATES.
CAUTION:
DO NOT GRIND. IT IS POSSIBLE TO REMOVE TOO MUCH MATERIAL WHEN GRINDING.
8. Assemble the brakes and caliper pins (E8TZ-2C150-B). Lubricate the caliper pins with disc brake lubricant (D7AZ-19590-A). Refer to the appropriate Light Truck Service Manual, Section 06-03, for assembling details.
9. Apply a light coat of disc brake lubricant (D7AZ-19590-A) to the inner knuckle top and bottom pad groove. Also apply a light coat of disc brake lubricant (D7AZ-19590-A) to the caliper rails.
CAUTION:
PREVENT LUBRICANT FROM STICKING TO ROTORS, LININGS OR CALIPER PISTON BOOTS.
PART NUMBER
WARRANTY STATUS AND OPERATION DESCRIPTION