Ford Falcon. Manual - part 64

206-03-5 

Front Disk Brake 

206-03-5

DIAGNOSIS AND TESTING

Front Disc Brake

Refer to Section 206-00

G96752 en

206-03-6 

Front Disk Brake 

206-03-6

REMOVAL AND INSTALLATION

3.  Using (G-clamps as shown), tighten until each

Brake Pads

piston bottoms on each bore.

Removal

NOTE: Ensure that one end of the G-clamp rests

on (or is adjacent to) the brake hose attaching

 WARNING: Although original equipment pad

bolt head, and the other against the outer pad.

material is asbestos free. If non genuine pads are

DO NOT exert excess force on the clamps as

used, the following applies:

damage to steel pistons may result.

Asbestos fiber dust may be present on brake

and clutch assemblies and is hazardous to

health if inhaled.
Brake and clutch assemblies should be

cleaned using a vacuum cleaner

recommended for use with asbestos fibers

such as a brake/clutch/service vacuum. The

bag must be labeled per OSHA instructions,

sealed, and the trash hauler notified as to the

bag’s contents.
If the vacuum suitable for asbestos is not

available, cleaning should be done wet. If dust

generation is still possible, technicians should

wear goverment-approved toxic dust purifying

respirators. Failure to follow these

instructions may result in personal injury.

Item

Description

1.  Clean and remove master cylinder reservoir cap.

1

Pad Abutment Bracket

Loosen front brake line connection at the master

2

Guided pin and boot assembly

cylinder, allowing fluid to bleed into a container

3

Guide pin bolt

until master cylinder reservoir is one-third full. Re

tighten line connection and replace master

4

Piston

cylinder cap.

5

Piston dust boot

6

Pad abutment shim

 WARNING: Brake fluid will damage

paintwork.

7

Pads

NOTE: Do not completely remove brake line or

4.  Using a suitable size open-end spanner to hold

empty the reservoir or it will be necessary to

the lower guide pin (7), remove and discard the

bleed the system.

guide pin bolt (3).

NOTE: Discard the fluid removed. DO NOT

NOTE: Old bolts must not be re-used, as they are

RE-USE.

vital safety components that have a micro

encapsulated adhesive on the bolt thread.

NOTE: Removal of the fluid is necessary to

prevent reservoir overflow when the caliper piston 5.  Disengage brake hose grommet from bracket

is pushed back in its bore during pad

attached with caliper mounting bolt.

replacement.

6.  Swing caliper housing about the existing guide pin

2.  With vehicle raised evenly on a hoist or jack

until housing is clear of pads.

stands, mark relationship of wheel to hub and

7.  Remove worn pads (7&8) from abutment bracket

remove the front wheels.

(7) and inspect condition of brake disc. Discard

Using wheel nuts secure rotor to hub during work.

end abutment shims (6).

NOTE: If more than one brake requires service,

8.  Check guide pins for free movement in abutment

work on only one brake at a time. Pad

bracket. If there is restriction of movement,

assemblies, must always be replaced in both

replace guide pins and/or guide pin boots.

brakes.

Including high lube grease.

9.  Clean any dirt from both the piston face, which

contacts the inner pad, and the caliper head area

that contacts the outer pad.

10. Inspect caliper assembly for fluid leaks or

damage.

G96753 en

206-03-7 

Front Disk Brake 

206-03-7

REMOVAL AND INSTALLATION (Continued)

Installation

Front Brake Hose

1.  Replace end abutment shims (6) in abutment

bracket (1), ensuring they are secure and clear of Removal

the rotor being careful not to bend them.

2.  Install the inner (7) and outer (8) pads to the

abutment bracket (1), against the inner and outer

surface of the brake disc respectively.

3.  Lower the brake calliper housing, ensuring that:

the piston boots (4&5) do not get caught

between the piston and inner pad (7).

4.  Install and tighten the new guide pin bolt (3) to the

correct torque specification.
NOTE: Do not wedge anything between the

guide pin hex and the caliper as it could cause

incorrect alignment of the free sliding of the

caliper relative to the anchor plate.

5.  Refit brake hose grommet to bracket attached to

Item

Description

caliper bracket, as previously positioned.

1

Clip

6.  Replenish the brake fluid in the master cylinder

2

Brake tube connector

with fresh specified fluid.

3

Banjo bolt

7.  Pump the brake pedal several times to position

the pad assemblies.

4

Grommet

8.  Check for fluid leakage at all connections under

1.  Remove banjo bolt and washers.

pedal pressure.

2.  Remove grommer from hose positioning bracket.

9.  Re-check fluid level in master cylinder reservoir.

3.  Disconnect the brake tube connector.

10. Remove wheel nuts.

4.  Remove clip (4).

11. Reinstall wheels, aligning marks made prior to

5.  Remove hose assembly.

removal and remove jack stands or lower hoist.

Installation

12. Tighten wheel, securing nuts to the specified

torque.

1.  Install banjo bolt and new washers. Torque to

specification.

13. Road test vehicle and make several light

60-0km/h stops to seat the linings. (The vehicle

2.  Install grommet into hose positioning bracket.

may pull slightly to one side for the first few

3.  Install hose into body bracket and install clip.

applications. This is normal until linings are

NOTE: Ensure hose is engaged to bracket prior to

seated)..

fitment of banjo bolt. Check routing for correct

clearance on completion.

4.  Connect brake tube and torque to specification.
5.  Bleed as outlined in procedure.

Brake Caliper Body

Removal
1.  Raise and support the vehicle to ensure it is

stable and secure. Mark the relationship of the

wheel and the rotor and remove wheel.

2.  Place a drain tray beneath caliper assembly.

Loosen and remove attaching bolt and hose end.

Discard washers and plug caliper body inlet port

and hose end to prevent contamination or fluid

loss.

G96755 en

206-03-8 

Front Disk Brake 

206-03-8

REMOVAL AND INSTALLATION (Continued)

3.  Disconnect hose. Discard copper sealing rings.

2.  Remove the caliper assembly from the spindle

and the rotor, as previously described in this

section. If the caliper does not require servicing, it

is not necessary to disconnect the brake hose.

Position the caliper out of the way, and support it

with a wire to avoid damaging the caliper or the

hose. Handle the rotor, linings and caliper

assemblies carefully to avoid deformation, nicking,

scratching or contamination.

3.  Remove the rotor from hub.
Installation
1.  Position the rotor on the axle flange.

NOTE: Ensure that all mounting surfaces are

clean and free from contamination which could

cause possible disc runout.

Installation

2.  Mount the caliper assembly on the spindle

following the Disc Brake Caliper Assembly

1.  Assemble caliper body to abutment bracket (1) by

Installation procedure in this section.

securing upper guide pin using a new guide pin

bolt (3).

3.  Install the wheel.

2.  Lower the brake caliper housing, ensuring that:
 

1.  the piston boots (4&5) do not get caught

between the piston and inner pad (7).

3.  Install and tighten the new guide pin bolt (3) to the

correct torque specification.
NOTE: Ensure hose is engaged to bracket prior to

fitment of banjo bolt. Check routing for correct

clearance on completion.
NOTE: Do not wedge anything between the guide

pin hex and the caliper as it could cause incorrect

alignment of the free sliding of the caliper relative

to the anchor plate.

4.  Reconnect new brake hose, using new, dry,

sealing washers. Tighten attaching bolt to the

correct torque specification ensuring hose routing

is removed.

5.  Bleed brake system, refer to Brake system Bleed

in this section.

Brake Disc

Removal
1.  Remove the wheel and tyre from the hub.

G96755 en