Attachment III - Technical Information
[NEW]OVERVIEWThis program provides coverage for replacing the rear brake pads when the friction material is below 3 mm (0.118 in). Rear brake rotors may or may not need to be machined or replaced, depending on the condition and thickness of the rotors. If the rear brake pads on an all wheel drive (AWD) Freestyle require replacement, it is also necessary to replace the front brake pads. It may or may not be necessary to machine or replace the front brake rotors, depending on the condition and thickness of the rotors.
SPECIFICATIONS
SERVICE PROCEDURE FOR REAR BRAKES
WARNING:
USE OF ANY OTHER THAN APPROVED DOT 3 MOTOR VEHICLE BRAKE FLUID WILL CAUSE PERMANENT DAMAGE TO BRAKE COMPONENTS AND WILL RENDER THE BRAKES INOPERATIVE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
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. FOR ADDITIONAL INFORMATION, CONSULT THE PRODUCT MATERIAL SAFETY DATA SHEET (MSDS) IF AVAILABLE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
CAUTION:
Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.
CAUTION:
Do not allow the brake fluid to come in contact with the adhesive backing on the brake pads. If brake fluid is spilled onto the brake pads, new pads must be installed.
CAUTION:
Use only specified brake parts cleaner. Use of other cleaners may leave a residue on the brake caliper, preventing the brake pad's adhesive surface from bonding with the brake caliper.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Check the brake fluid level in the brake fluid reservoir.
If required, remove fluid until the brake master cylinder reservoir is half full.
3. Remove the rear wheel and tire assemblies.
4. Remove the brake caliper bolts.
CAUTION:
Do not use the brake caliper sight hole to retract the pistons as this can damage the pistons and boots.
CAUTION:
Do not allow the caliper to hang from the brake hose or damage to the hose can occur.
CAUTION:
Care must be taken when servicing rear brake components without disconnecting the parking brake cable from the brake caliper lever. Carefully position the caliper aside using a suitable support or damage to the parking brake cable end fitting can occur.
5. Using hand force and a rocking motion, separate the brake caliper from the anchor plate.
Position the brake caliper aside.
^ Support the caliper with mechanic's wire.
6. Remove and discard the brake pads and spring clips from the brake caliper anchor plate.
7. Measure the thickness of the brake discs. Refer to the Specifications at the beginning of this Attachment III.
^ If there is no brake vibration reported by the customer, the brake disc(s) are not heavily scored and the disc(s) measures above the minimum thickness specification, it is not necessary to machine or replace the brake disc(s). Proceed to Step 11.
^ If the disc(s) measures at or above the minimum thickness to machine specification and there is heavy scoring on the rotor or the customer complains of a brake vibration, proceed to the Service Procedure For Machining Brake Disc in this Attachment III.
^ If the disc(s) measures below the minimum thickness specifications, proceed to the next step.
NOTE:
If the brake disc on one side of an axle needs to be replaced or machined, it is necessary to machine the brake disc on the other side of the same axle. Example: If the brake disc on the right rear side is below the minimum thickness specification but the disc on the left rear side is above the minimum thickness to machine specification, it is necessary to replace the right rear side disc and machine the left rear side disc. If this vehicle is an AWD Freestyle, the front axle should be evaluated in the same manner.
8. Remove the brake caliper anchor plate bolts and discard.
9. Install disc(s) and new attachment screw(s).
10. Install brake caliper anchor plate and new bolts. Tighten the bolts to 110 Nm (81 lb-ft).
CAUTION:
The LH caliper piston turns clockwise and the RH caliper turns counterclockwise. Turning the caliper piston in the wrong direction will cause the piston to come out of the caliper, which will require caliper replacement. Caliper replacement is not covered under this program.
11. Using the Rear Caliper Piston Adjuster 206-026 (T87P-2588-A), compress the brake caliper piston into its cylinder. See Figure 1.
12. Clean the residual adhesive from the brake caliper fingers and pistons using Metal Brake Parts Cleaner PM-4-A Or PM-4-B (US); CPM-4 (Canada).
CAUTION:
Do not allow grease, oil, brake fluid or other contaminates to contact the brake pad or caliper mating surface.
NOTE:
Install all the new hardware supplied with the brake kit.
13. Install the new spring clips and brake pads.
14. Position the brake calipers and install the bolts. Tighten the bolts to 31 Nm (23 lb-ft).
^ If the vehicle is a AWD Freestyle, install the rear wheel and tire assemblies, tighten the nuts to 133 Nm (98 lb-ft) and proceed to the Service Procedure For AWD Freestyle Front Brakes.
^ If the vehicle is not a AWD Freestyle, proceed to the next step.
15. If necessary, fill the brake fluid reservoir with clean, High Performance DOT3 Motor Vehicle Brake Fluid PM-1 or PM-1-C (US); CPM-1 Or CPM-1-C (Canada).
16. With the vehicle engine running, apply 20-30 lb of pressure on the brakes for approximately 1 minute, to make sure the brake pads adhere to the caliper before any contamination can be introduced.
17. Install the rear wheel and tire assemblies and tighten the nuts to 133 Nm (98 lb-ft).
18. Test the brakes for normal operation.
SERVICE PROCEDURE FOR AWD FREESTYLE FRONT BRAKES
WARNING:
USE OF ANY OTHER THAN APPROVED DOT 3 MOTOR VEHICLE BRAKE FLUID WILL CAUSE PERMANENT DAMAGE TO BRAKE COMPONENTS AND WILL RENDER THE BRAKES INOPERATIVE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
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.
FOR ADDITIONAL INFORMATION, CONSULT THE PRODUCT MATERIAL SAFETY DATA SHEET (MSDS) IF AVAILABLE. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
CAUTION:
Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.
CAUTION:
Do not allow the brake fluid to come in contact with the adhesive backing on the brake pads. If brake fluid is spilled onto the brake pads, new pads must be installed.
CAUTION:
Use only specified brake parts cleaner. Use of other cleaners may leave a residue on the brake caliper, preventing the brake pads adhesive surface from bonding with the brake caliper.
1. Remove the front wheel and tire assemblies.
2. Using a large C-clamp, compress the pistons into the caliper housing.
Position one end of the C-clamp on the outer pad between the caliper fingers, the other end on the caliper housing. During this process, the outer brake pad will separate from the caliper housing.
3. Remove the brake caliper guide pin bolts.
NOTE:
The brake pads must be separated from the brake caliper before the brake caliper can be removed from the brake caliper anchor plate.
4. Separate the inner brake pad from the caliper.
CAUTION:
Do not allow the caliper to hang from the brake hose or damage to the hose can occur.
5. Position the caliper aside.
Support the caliper using mechanic's wire.
6. Remove the brake pads and spring clips from the brake caliper anchor plate and discard the retraction clips.
7. Clean the residual adhesive from the brake caliper-to-brake pad mating surfaces using Metal Brake Parts Cleaner PM-4-A or PM-4-B (US); CPM-4 (Canada).
SERVICE PROCEDURE FOR MACHINING BRAKE DISC
NOTE:
If performing the Service Procedure For AWD Freestyle Front Brakes, make sure the steering stop is supported when the brake caliper anchor plate bolts are removed.
1. Remove the brake caliper anchor plate bolts and discard.
2. Mark the brake disc and the wheel stud for correct indexing during re-assembly.
3. Remove the attachment screw and brake disc from hub.
CAUTION:
Do not use an abrasive sanding disc since it will remove paint or other protective finishes from the wheel or metal from the mounting surfaces, adversely affecting corrosion protection and brake disc lateral runout.
4. Remove corrosion from the wheel mounting surface, both brake disc mounting surfaces and hub mounting surface.
5. Align the match marks, install the brake disc on the hub and install the attachment screw.
6. Machine the brake disc using an on-vehicle brake lathe.
a) Install the hub adapter and silencer belt, if necessary.
b) Install the cutting lathe.
c) If the lathe is not self-adjusting, adjust the lathe oscillation using a dial indicator. Total indicated reading (TIR) target is 0.00 mm (0.000 in), maximum is 0.08 mm (0.003 in).
d) Center the cutting head, adjust the cutting bits and install the chip deflector.
NOTE:
The depth cut should be between 0.10 and 0.20 mm (0.004 and 0.008 in). Lighter cuts will cause the bit to heat up and wear faster. Faster cuts will cause poor brake rotor surface finish.
e) Machine the brake disc.
f) Remove the lathe and, if installed, the silencer belt.
g) Remove the hub adapter.
7. Remove the metal shavings.
8. Remove the attachment screw and discard.
9. Remove the brake disc from the hub.
10. Remove metal shavings from the hub, brake disc mounting surfaces and from the ABS sensors.
11. Apply anti-seize lubricant to the hub mounting surface to prevent corrosion.
12. Align the match marks and install the brake disc on the hub and install the new attachment screw.
13. Proceed to Step 10 in the Service Procedure For Rear Brakes or Step 11 in the Service Procedure For AWD Freestyle Front Brakes.