Ford Falcon. Manual - part 66

206-04-2 

        Rear Disc Brake           206-04-2

SPECIFICATIONS

General Specifications

Description

Specification

Rear disc brake minimum

14.5mm (0.57in)

thicknessª
Lubricants
High melting point grease Dow Corning 44/Niglube

Rx2

Pad
Lining wear limit

1.0mm

Material

JBUF85FF

Torque Specifications

Description

Nm

Brake caliper bolts

103

Brake disc shield bolts

11

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206-04-3 

        Rear Disc Brake           206-04-3

DESCRIPTION AND OPERATION

Rear Disc Brake

Rear Disc Brake System Components

Parking Brake

The parking brake utilizes a cable operated rear drum

system. For additional information, refer to Section

206-05.

Item

Description

1

Knukle

2

Wheel hub

3

Washer

4

Nut

5

Rotor

6

Brake Caliper

7

Bolt

The rear wheel disc brake assembly consists of a

rotor mounted on the outer face of the axle shaft

flange and a single piston floating head caliper. A

splash shield, used primarily to prevent road

contaminants from contacting the inboard rotor and

pad surface is also mounted on the anchor bracket.
The outboard rotor and pad surfaces are protected by

the road wheel.

Service Brake

When the brake pedal is applied, brake fluid is

displaced into the caliper bore moving the piston

outward. This action forces the inner pad assembly

against the rotor. The resultant reaction forces the

caliper body and outboard pad assembly inward

against the rotor. Braking torque is transferred from

the outer and inner pad assemblies to the caliper

mounting bracket. When the brake pedal is released,

the piston seal retracts the piston a small amount

allowing the pads to release the clamping force.

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206-04-4 

        Rear Disc Brake           206-04-4

DIAGNOSIS AND TESTING

Brake Calipers

Refer to Section 206-00.

Inspection

1.  Clean all residue from disc pad guide surfaces on

anchor bracket and caliper housing assembly.
NOTE: Always replace both axle caliper pads as

a set.

2.  Inspect inner and outer pads. Lining wear limit is

1.0 mm.

3.  Inspect anchor bracket. Replace anchor bracket if

corroded, worn or damaged.

4.  Clean piston, housing and bleed screw. Use only

clean denatured alcohol for cleaning. Dry, filtered

compressed air should be used to dry all

components and blow out all passages in the

caliper housing and bleed screw. Care should be

taken to keep alcohol and debris away from eyes.

 CAUTION: All components must be kept

away from any type of mineral oil as it will

damage rubber components.

5.  Inspect piston. Replace piston if scoring, nicks,

corrosion, wear or damage is evident.

6.  Inspect housing. Replace housing if bore is

scored, corroded, worn or damaged.

7.  Lubricate seal and housing bore with silicone

grease or brake fluid.

8.  Lubricate piston with brake fluid.

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206-04-5 

        Rear Disc Brake           206-04-5

REMOVAL AND INSTALLATION

2.  Remove caliper mounting bolts.

Brake Caliper Body

Removal
NOTE: Where the use of brake fluid is required, use

only new, clean fluid to the correct specification, from

a sealed container.

1.  Raise the vehicle and remove the wheel.
2.  Use wheel nut to hold disc in place.
3.  Remove banjo bolt and hose end. Discard

washers. Plug housing inlet port and hose end to

prevent contamination ingress or fluid loss.

4.  Remove guide pin bolts (items 1 and 2) and

discard.

Installation

3.  Lift caliper free of rotor.

1.  Place caliper housing assembly into its operating

4.  To install reverse steps 1-3.

position. If springs are sticking through caliper

housing inspection hole, lift caliper housing and

Rear Brake Hose

make necessary corrections to ensure springs are

fully retained by housing.

Removal

2.  Install new guide pin bolts.
3.  Assemble banjo bolt, washers and hose end then

screw into housing inlet port. Torque guide bolts

to 28-34 Nm. Torque banjo bolt to specification.
NOTE: Ensure hose is engaged to bracket prior to

fitment of banjo bolt. Check routing for correct

clearance on completion.

4.  Bleed brakes ensuring that fluid reservoir is not

emptied. Start engine and pump brake pedal

slowly and firmly three times to ensure piston and

disc pads resume normal operational position.

Torque bleed screw to 9-14 Nm. Check for fluid

leakage and rectify if any found. Check fluid level

in master cylinder reservoir and fill to specified

level with new brake fluid.

Item

Description

NOTE: All hardware must be correctly installed

1

Rivot

and torqued to specification.

2

Rear Tube Connection

5.  Install wheel and torque nuts to specification.

3

Grommet

Brake Caliper Assembly

4

Banjo  Bolt

Removal and Installation

1.  Disconnect rear brake tube connection.

1.  Repeat steps 1 & 2 of brake caliper body removal. 2.  Drill out rivot.

3. Remove 

grommet.

4.  Remove banjo bolt.

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