Service Procedure

Figure 1:

1. Check and adjust brake pad clearances and caliper knuckle clearances as follows:

a. Remove the pins from the caliper.

b. While holding the caliper in place against the bottom pin rails, Figure 1, measure the clearance between the caliper and the top pin rails. Clearance should be a minimum of .015 ".

c. If the clearance is insufficient, replace the caliper and measure again. If clearance concern still exists, replace the knuckle.

NOTE: CHECK THE CLEARANCE ON THE NEW KNUCKLE BEFORE INSTALLATION.

d. After measuring the caliper/knuckle for proper clearances, remove both calipers and inner pad assemblies.

e. Remove the anti-rattle clip from the inner pad.

Figure 2:

Figure 3:

f. Re-install pad and check the side and end clearances with a feeler gauge. (See Figure 2 for clearance dimensions.)

g. If the pad clearances are within specification, refer to Service Procedure Step 2 - "Caliper Groove Lubrication". If the pad clearances are not to the required dimensions, file the steel backing plate.

WARNING: USE SAFETY GLASSES WHEN FILING STEEL BACKING PLATES

h. File material, removing equal amounts from both sides or ends. (See Figure 3.)

CAUTION: DO NOT GRIND. IT IS POSSIBLE TO REMOVE TOO MUCH MATERIAL WHEN GRINDING.

i. Check the tab clearances and install anti-rattle clip on the lower pad tab, Figure

2.

2. Apply a light coat of lubricant (D7AZ-19590-A) to the inner knuckle top and bottom pad groove and caliper rails.
CAUTION: MAKE SURE THE LUBRICANT DOES NOT GET ON THE ROTORS, LININGS, OR ON THE CALIPER PISTON BOOTS.

3. Replace the right and left side arm bushings with new bushings (FlTZ-3B203-A). Refer to the appropriate Light Truck Shop Manual, Section 04-OIC for service details.

NOTE: THE EXPLORER IS ALREADY EQUIPPED WITH THE NEW RADIUS ARM BUSHINGS.