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Front brake pads - renewal
Braking system / Front brake pads - renewal


Warning: Disc brake pads must be renewed on both front wheels at the same time - never renew the pads on only one wheel, as uneven braking may result. Although genuine Ford linings are asbestos-free, the dust created by wear of non-genuine pads may contain asbestos, which is a health hazard. Never blow it out with compressed air, and don’t inhale any of it. DO NOT use petroleum-based solvents to clean brake parts; use brake cleaner or methylated spirit only. DO NOT allow any brake fluid, oil or grease to contact the brake pads or disc. Also refer to the warning at the start of Section 15 concerning brake fluid.

1 Apply the handbrake. Loosen the front wheel nuts, jack up the front of the vehicle and support it on axle stands.

2 Remove the front wheels. Work on one brake assembly at a time, using the assembled brake for reference if necessary.

3 Follow the accompanying photos, beginning with illustration 2.3A, for the pad removal procedure. Be sure to stay in order, and read the caption under each illustration.

2.3A Prise the retaining clip from the caliper. Hold it with a pair of
2.3A Prise the retaining clip from the caliper. Hold it with a pair of pliers, to avoid personal injury. On models fitted with pad wear sensors, it will be necessary to disconnect the wiring

2.3B Prise the plastic covers from the ends of the two guide pins
2.3B Prise the plastic covers from the ends of the two guide pins

2.3C Using a 7 mm Allen key, unscrew . . .
2.3C Using a 7 mm Allen key, unscrew . . .

2.3D . . . and remove the guide bolts securing the caliper to the carrier
2.3D . . . and remove the guide bolts securing the caliper to the carrier bracket

2.3E Withdraw the caliper from the disc, and support it on an axle stand to
2.3E Withdraw the caliper from the disc, and support it on an axle stand to avoid straining the hydraulic hose. The outer pad will normally remain in position against the disc, but the inner pad will stay attached to the piston in the caliper

2.3F Pull the inner pad from the piston in the caliper
2.3F Pull the inner pad from the piston in the caliper

2.3G Remove the outer pad from the caliper frame. Brush all dust and dirt
2.3G Remove the outer pad from the caliper frame. Brush all dust and dirt from the caliper, pads and disc, but do not inhale it, as it may be harmful to health. Scrape any corrosion from the disc.

4 Inspect the front brake disc for scoring and cracks. If a detailed inspection is necessary, refer to Section 4.

5 The piston must be pushed back into the caliper bore, to provide room for the new brake pads. A C-clamp can be used to accomplish this. As the piston is depressed to the bottom of the caliper bore, the fluid in the master cylinder will rise slightly. Make sure that there is sufficient space in the brake fluid reservoir to accept the displaced fluid, and if necessary, syphon some off first.

6 Fit the new pads using a reversal of the removal procedure, but tighten the guide bolts to the torque wrench setting given in the Specifications at the beginning of this Chapter.

7 On completion, firmly depress the brake pedal a few times, to bring the pads to their normal working position. Check the level of the brake fluid in the reservoir, and top-up if necessary.

8 Give the vehicle a short road test, to make sure that the brakes are functioning correctly, and to bed-in the new linings to the contours of the disc. New linings will not provide maximum braking efficiency until they have bedded-in; avoid heavy braking as far as possible for the first hundred miles or so.


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