Ford Falcon. Manual - part 67

206-04-6 

        Rear Disc Brake           206-04-6

REMOVAL AND INSTALLATION (Continued)

Installation

4.  Position a C-clamp so that one end rests on rear

of caliper housing and the other end against outer

1.  Install high tensile rivot.

disc pad. Tighten clamp until piston bottoms in

base of caliper housing.

2.  Connect tube to hose end.
3.  Install hose grommet into bracket.

5.  Remove and discard upper guide pin bolt.

4.  Install banjo bolt through hose and into caliper.

6.  Rotate caliper housing about lower caliper

NOTE: Ensure hose is engaged to bracket prior to

mounting bolt and guide pin. Be careful not to

fitment of banjo bolt. Check routing for correct

strain hose.

clearance on completion.

7.  Remove inner and outer pads.

NOTE: Ensure fitment of new copper washers.

NOTE: Always replace both axle caliper pads as

a set.

Brake Pads

8.  Clean all residue from disc pad guide surfaces on

anchor bracket and caliper housing.

Removal

9.  Inspect guide pins for free movement in anchor

 WARNING: Although original equipment pad

bracket. Replace guide pins or boots if corroded

material is asbestos free. If non genuine pads are

or damaged.

used, the following applies:

Installation

Asbestos fiber dust may be present on brake

1.  Install new pads on anchor bracket. Apply

and clutch assemblies and is hazardous to

approximately 0.1 gram of AKB-100 grease (or

health if inhaled.

equivalent) to pad abutment surfaces on the

Brake and clutch assemblies should be

anchor bracket.

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.

1.  Siphon approximately two-thirds of the total fluid

capacity from the master cylinder reservoir.

Discard the fluid (different to front brake).

2.  Rotate caliper housing into its operating position.

2.  Raise the vehicle and remove wheels.

3.  If springs are sticking through caliper housing

3.  Install two wheel nuts to retain rotor.

inspection hole, lift caliper housing and make

necessary corrections to ensure springs are fully

retained by housing.

4.  Install new upper guide pin bolt and torque to

28-34 Nm.

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206-04-7 

        Rear Disc Brake           206-04-7

REMOVAL AND INSTALLATION (Continued)

5.  Top up master cylinder.

Beam Axle Brake Disc

6.  Start engine and pump brake pedal slowly and

Removal

firmly three times to ensure piston and disc pads

resume normal operating position.

1. Raise 

the 

vehicle.

7.  Check for fluid leakage and rectify if any found.

2.  Wipe all dirt and grease from the brake pipe union

Check fluid level in master cylinder reservoir and

and disconnect the union.

fill to specified level with new brake fluid.

3.  Detach the flexible hose from the splash shield

8.  Remove nuts retaining rotor and install wheels.

bracket and plug the pipe and hose.

9.  Lower vehicle and torque wheel nuts to

4.  Remove the three screws attaching the splash

specification.

shield to the axle flange.

Installation

Brake Disc

1.  Position the splash shield and install the attaching

Removal

screws.

1.  Raise the vehicle and remove the rear wheels.

2.  Fit the flexible hose to the splash shield bracket

and secure it with the locknut.

2.  With the park brake control released disconnect

the park brake cable at the equalizer.

3.  Remove the dust plugs and fit the pipe to the

hose.

4.  Bleed the brakes as described in Section 206-00.
5.  Lower the vehicle.

3.  Disconnect the cable from the levers.
4.  Remove the caliper head attaching bolts and

remove the caliper assembly from the rotor and

mounting bracket.

 CAUTION: Do not allow the caliper to

hang from the hydraulic line.

5.  Remove the screw securing the rotor to the axle

flange and remove the rotor (for beam axle only).

Installation
1.  Position the rotor on the axle flange, ensuring that

all mounting surfaces are clean and free from

contamination which could cause possible disc

run-out. Install the securing screw.

2.  Position the caliper correctly over the rotor and

slide straight into location until caliper head bolt

holes align with their respective holes in the

mounting bracket.

3.  Install caliper mounting bolts and torque to

specification.

4.  Connect the park brake cables to the levers and

the equalizer. Adjust the park brake as described

in Section 206-05

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206-04-8 

        Rear Disc Brake           206-04-8

DISASSEMBLY AND ASSEMBLY

Brake Caliper

Disassembly

4.  Remove piston (item 12). Pack a clean shop towel

Item

Description

between piston and housing finger then apply low

1

Bleed  Screw

air pressure at housing inlet port to remove piston.

2

Caliper Housing

 CAUTION: Apply light air pressure

3

Anchor Bracket

initially and progressively increase until piston

4

Outer Disc Pad

is forced out of bore. While removing piston

5

Boot

keep hands away from piston/housing region

to avoid personal injury, as the piston may

6

Guide  Pin

develop considerable force due to air

7

Inner Disc Pad

pressure.

8

Boot

5.  Remove boot and seal using a small, pointed tool

9

Piston

as per Section 206-03. Be careful not to damage

10

Seal

the bore or seal groove. Discard.

11

Lower Mounting Bolt

6.  Remove bleed screw (item 15) and dust cover

(item 16). Discard dust cover.

12

Inlet Port

13

Upper Guide Pin Bolt

Assembly

1.  Remove brake caliper as described in this

1.  Lubricate seal (item 13) and housing bore with

section.

silicone grease or brake fluid.

2.  Remove housing assembly (item 9), guide pins

2.  Lubricate piston with brake fluid.

(items 3 and 4) and boots (items 5 and 6).

3.  Install new seal (item 13) into housing bore seal

Discard boots. Plug anchor bracket (10) colette

groove and ensure that it is not twisted.

pinholes (A) to prevent contamination ingress.

NOTE: Ensure hose is engaged to bracket prior to

3.  Remove disc pads (items 7 and 8).

fitment of banjo bolt. Check routing for correct

clearance on completion.

G86759 en

206-04-9 

        Rear Disc Brake           206-04-9

DISASSEMBLY AND ASSEMBLY (Continued)

4.  Install new boot (item 14) and piston. Install boot

8.  Install disc pads on anchor bracket with outer disc

over open end of piston and feed along piston

pad with clip-on insulator toward caliper housing

length towards closed end. Fully extend boot

finger and inner disc pad with lining wear sensor

away from piston closed end with boot still on

toward caliper piston.

piston ground surface. Install boot into housing

bore boot groove and ensure full engagement.

5.  Slowly enter piston into bore by hand, then apply

steady pressure by hand to piston and press until

piston is fully seated in the bore. This process will

ensure that boot and seal are correctly positioned

in conjunction with no piston/housing bore

scoring.

6.  Inspect piston and boot. Check that boot is

properly engaged in piston groove correctly.

7.  Assemble dust cover and bleeder screw, then

screw into housing.

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