206-00-1

Brake System

206-00-1

REMOVAL AND INSTALLATION

Front Disc Brake
Material
Item

Specification

High Performance DOT 3

Motor Vehicle Brake Fluid
PM-1 (Canada CXC-31)
High Temperature Nickel
Anti-Seize Lubricant
XL-2
Silicone Brake Caliper
Grease and Dielectric
Compound
XG-3

ESA-M6C25-A, DOT 3

ESE-M12A4-A

ESE-M1C171-A

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: 1-800-959-3673. 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 or plastic surfaces. If brake fluid is
spilled onto a painted or plastic surface,
immediately wash it with water.
1.

Remove the front wheel and tire assemblies.

For additional information, refer to Section
204-00.

2.

Remove the parts in the order indicated in the

following illustration and table.

To remove individual parts, only carry out the

listed steps:
Part

Steps

Brake caliper

1-2, 10, 11

Brake disc pads

1-4

Anchor bracket

1-8

Brake disc

5, 9

Brake hose

10-15

Brake disc shield

5, 9, 12

Copyright 2002, Ford Motor Company

Last updated: 6/5/2006

2003 Explorer/Mountaineer, 9/2002

206-00-2

Brake System

206-00-2

REMOVAL AND INSTALLATION (Continued)

Item

Part Number

Description

2W303

2B294/2B302

2001

4
5

2027

Caliper bolts
Installation Note
Brake caliper (RH/LH)
Removal Note
Brake disc pads
Installation Note
Slippers (part of kit 2001)
Anchor bracket bolt kit (one
kit each side)
Removal Note

(Continued)

Item
6

Part Number

1125

10

385116-S2

Description
Anchor bracket (part of kit
2B296/2B513)
Guide pin and boot (part of
kit 2B296)
Installation Note
Locating pin and boot (part
of kit 2B296)
Installation Note
Brake disc
Installation Note
Flow bolt

(Continued)

2003 Explorer/Mountaineer, 9/2002

206-00-3

Brake System

206-00-3

REMOVAL AND INSTALLATION (Continued)

Item
11
12
13
14
15

Part Number
2149
2L385
W505223-S
2B556/2B557

Description
Copper washers
Brake disc shield
Installation Note
Brake hose bracket bolt
Brake hose (RH/LH)
Brake tube

3.

To install, reverse the removal procedure.

4.

If the hydraulic system has been opened, bleed

the brake system. For additional information,
refer to Brake System Bleeding in this section.

5.

Inspect the brake system for proper operation.

Item 2: Brake Caliper Removal Note

1.

2.

CAUTION: Do not allow the brake

caliper to hang by the flexible brake hose.

Item 9: Brake Disc Installation Note

1.

Support the caliper to the vehicle.

Item 5: Anchor Bracket Bolt Kit Removal
Note
1.

2.

If removing the brake disc, only remove the

caliper bracket bolts and position the caliper
and bracket aside.

Secure the brake disc shield to the wheel

knuckle with three 6.35 mm (0.25 in) rivets
(W701950-S100).

CAUTION: Make sure to apply a thin

coat of anti-seize lubricant to the hub flange
only. Do not allow the lubricant to make
contact with the wheel studs, brake pads or
brake disc.
Apply a thin coat of anti-seize lubricant to the
wheel hub flange.

Item 8: Locating Pin and Boot Installation

Note

CAUTION: Do not allow the brake

caliper and bracket assembly to hang by the
flexible brake hose.

1.

Make sure that the locating pin and boot

assembly are in the bottom hole.

Support the caliper and bracket assembly to the

vehicle.

2.

Lubricate the locating pin and boot with

silicone brake caliper grease.

Item 12: Brake Disc Shield Removal Note

Item 7: Guide Pin and Boot Installation Note

1.

1.

Make sure that the guide pin and boot assembly

are in the top hole.

2.

Lubricate the guide pin and boot with silicone

brake caliper grease.

Remove and discard the shield bolts.

Item 12: Brake Disc Shield Installation Note

1.

Drill three 6.35 mm (0.25 in) holes in the

wheel knuckle.

Item 3: Brake Disc Pads Installation Note

1.

One brake disc pad kit contains the pads

required for both sides.

Item 1: Caliper Bolts Installation Note

1.

Tighten the bottom bolt and then the top bolt.

2003 Explorer/Mountaineer, 9/2002