Ford Escort rear disc brake conversion - Mechanical Database

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Ford Escort rear disc brake conversion
This article is primarily intended for the Ford Escort, however should also work for the following list of cars:
91-96 Ford Escort GT
91-96 Mercury Tracer LTS
90-94 Mazda Protege
90-94 Mazda 323
92-95 Mazda MX3 GS (V6)
97-02 Ford Escort/ZX2
97-99 Mercury Tracer

The rear disc brake system consists of a solid rear disc brake rotor and a single-piston rear disc brake caliper. The rear brake pads and linings are held in position
between the rear disc brake caliper and the rear disc brake rotor by two guides, two shims, and an M-spring. It is not necessary to remove the rear disc brake
caliper completely to replace the rear brake pads and linings; the rear brake pads and linings can be removed simply by pivoting the rear disc brake caliper on its
rear disc support bracket
Hydraulic power is provided to the rear disc brakes by a rear wheel brake hose attached to the rear disc brake caliper (which can be replaced with Stainless steel
brake lines). Replaceable copper washers on either side of the rear wheel brake hose fitting prevent brake fluid leakage.

Rear Disc Brake Assembly
1. Rear Wheel Spindle
2. Rear Disc Support Bracket
3. Rear Wheel Disc Brake Shield
4. Wheel Hub
5. Rear Disc Brake Rotor
6. Rear Disc Brake Rotor Screw (2 Req'd)
7. Rear Axle Wheel Hub Retainer
8. Hub Grease Cap
9. Guide
10. Shim
11. Brake Pad
12. M-Spring
13. Rear Disc Brake Caliper
14. Brake Caliper Bolt
15. Copper Washer (2 Req'd)
16. Banjo Bolt
17. Rear Wheel Brake Hose

The parking brake rear cable and conduit (2A635) is attached to the rear disc brake
caliper at the rear brake operating lever (2N512). When the parking brake is applied, the
rear brake operating lever pushes the brake connecting link (2Z999) against the piston, which forces application of the rear brake pads and linings. When the
parking brake is released, pressure against the piston is released and the rear brake pads and linings return to their unapplied position.

Parking Brake
1. Parking Brake Rear Cable and Conduit
2. Rear Drum Brake
3. Rear Disc Brake
4. Front Parking Brake Cable and Conduit
5. Parking Brake Lever

Tool List
1. Ratchet
2. Breaker Bar
3. Sockets - 10mm, 12mm, 14mm, 16mm, 17mm, 21mm (32mm
needed for hub retainers).
4. 10mm and 17mm deep sockets
5. 1/4" socket
6. #1 Phillips Head Screwdriver Bit
7. 10mm flare nut "line" wrench
8. 8mm box end wrench
9. 4mm Allen wrench
10. Needle Nose Pliers
11. 4lb. Sledge Hammer (or equivalent)
12. Jack
13. Jack Stands
14. Drill or rotary tool with wire brush, or sandblasting cabinet

Obtaining Major Parts

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Remove the rear wheels from the car using a lug wrench or a 21mm socket. The optimum choice for a donor car would have the lowest miles possible.php/Ford_Escort_rear_disc_brake_conversion Rear disc assemblies that fit the ZX2. and do the same to the other nut. Repeat this procedure for the other cable. The parking brake cable should only be connected to the caliper. then they are in good shape. 5. slide the brake hose off each strut and position the brake hoses aside. 8. remove the 1 bolt and 1 nut holding the cable to the car. Using a deep 10mm socket. Remove the spindle from the struts and trailing arms. This is usually a more expensive route. Using a 12mm socket. Using a pair of pliers. Place the breaker bar on one of the nuts holding the strut to the Database 2 of 8 http://mechdb. 3. Put a regular 17mm socket on a ratchet. Since the control arms will be seized to the spindle. and trying to move it from side to side. The heat shields may have to be removed with a 10mm socket to expose them. they will hold up to weather and can be restored to good working order. 6. 2. 5. This also helps avoid being beneath the car and also provides better leverage when needed. 4. This is done by spinning the hub on the spindle. 6/1/2015 7:23 PM . From under the car. Remove the front end of e-brake cables. loosen the the adjusting nut beside the e-brake handle. 9. Make sure the e-brake is not engaged. This will provide slack on the cable system. The entire assembly can be rebuild. and bolted to the car in 2 places. Knock the trailing arm off the spindle with the 4lb. sledge. The parking brake cables are attached to the car at both ends. and one that has not been in a junkyard for an extended period of time. Verify that the car is securely supported by jack stands or similar. 4. locate the cables on each side of the car.Ford Escort rear disc brake conversion . Put a 17mm deep socket on a breaker bar. 2. it easiest to work on the brakes with the crossmember fully removed from the car. It may be necessary to remove the center spring to provide even more slack on the cables to remove them. as long as your local junkyard permits it. In order to test the hub. as most often the brake pads are stuck to the rotor. 3. and there is minimal movement side to side. 7. the caliper should be removed. The entire crossmember will drop from the car and can be pulled out from underneath. Disconnect the brake lines at the crossmember. Remove the clip near the front of the cable. 2nd. Since the major portion of the setup is made of cast iron though. and harder to get if it needs to be shipped. loosen and remove the bolt that holds the trailing arm to the bottom rear of the spindle. and replaces the existing crossmember. Repeat on other side. and pull the front of the cable out of the front assembly. Break the nut loose. and 3rd gen Ford Escorts are available from the cars listed in the beginning of this article. The easiest method for putting rear disc brakes on a ZX2 is to buy the entire crossmember assembly from a ZX2 S/R (or 97-02 Escort with rear disc brakes). Repeat this on the other spindle/strut. If it spins fairly well. and the ratchet on the bolt side. The hub needs to be checked to see if the bearings are good. Rear Disc Removal 1. To do this: 1. The most cost effective way to get rear discs is to remove them yourself.

Depending on the shape of the screw heads. 2. so as not to damage the dust shields.php/Ford_Escort_rear_disc_brake_conversion 14. ratchet and 17mm sockets. locate the brake line distribution block on the crossmember. Using the breaker bar. 12. Underneath the vehicle. e-brake cables. Using the breaker bar. you can clean them all up. You can attempt to remove the front control arms that are held onto the spindle with a 17mm nut. to allow replacement of the brake pads. The first thing you can do is remove the calipers. and remove it.Ford Escort rear disc brake conversion . take it home. Either use a line wrench to remove the lines coming from the front of the car. The rear calipers are designed to swing open on the spindle. The endlinks are easier to just cut with large bolt cutters. 4. This should loosen the caliper from the brake pads. While you have the crossmember on the ground. or cut them with bolt cutters. remove the 4 bolts (2 on each side) holding the crossmember to the car. since the rotors are more than likely stuck to the brake pads. Disassembly 1. rebuild if necessary. 16. and will be easier to take off when you get home. including the control arms. using a 12mm socket on the banjo bolts. 14mm socket and ratchet. and put them on. Remove the sway bar bracket bolts (14mm) and the endlinks. 13. and dust shields. Once you have it all apart. loosen the adjuster screw inside. but the bushings are usually seized to the bolt. 3. now is a good time to remove the 21mm rear sway bar. The first thing to try to do is loosen the screws holding the rotors to the hubs. locate the black plastic dust cap.Mechanical Database 3 of 8 http://mechdb. you might be able to remove them. Remove the bolts and nuts holding the spindle to the struts and lower the crossmember to the ground. hubs. you can just drill them out later. Now that you have it all loose. Using a 4mm allen wrench. 11. You should now have the complete brake assembly. remove the 14mm bolt on the rear of the caliper. Once these pieces are off. you can start working on getting the dreaded bolt out of the spindle that holds the control arms. Now it's time to prepare them to put on the car. don't worry about them. If they can't be loosened without stripping the head. Carefully slide the assembly out from under the car. which will retract the piston back into the caliper. Remove the brake lines from each caliper. On the caliper. remove the nuts and bolts holding the control arms to the crossmember. 6/1/2015 7:23 PM . 15. The idea is to try to loosen them now. with a suitable Phillips bit in conjunction with a socket. adapters and a breaker bar. To do this.

Remove the clip and pull the cable away. Cutting the bolt off flush at the spindle. If you were successful in removing the screws. 9. 10. trying not to bend it up. Unstake the hub retainer by punching the indentation out of the spindle. as shown. Those are the pieces used to make the spacers. remove the "M" springs from the pads using a pair of needle nose pliers. Removin the bolt is the most difficult task in the conversion (the second is getting the bolts off your drum spindles). break the bolts holding the caliper bracket to the spindle. Certain materials in brake pads are hazardous to your health and inhaling them should be avoided when possible. drill them down until just past the rotor. Using a press to push the bolt out. give the rotors a few bangs with the sledge hammer to loosen them from the hub. 13. etc. The calipers are attached to the caliper with a clip. Note the 2 pieces above the 4 long bolts.). The spacer needs to be approximately 3/4" thick. then pull slightly on the cable to remove it from the bracket. until it comes loose. The pads should slide off of the caliper bracket. the old rusty rotors can come off. If you have newer rear brakes (from an S/R.Mechanical Database 4 of 8 with nothing left attached but the control arms.php/Ford_Escort_rear_disc_brake_conversion 5. Use a pair of wrenches to loosen the lock nut.Ford Escort rear disc brake conversion . Taking it to a shop. and at least one of the sleeves on either side from the control arms. 7. 6/1/2015 7:23 PM . The ultimate method is to get them sandblasted. Slowly the bolt will begin to rotate as the metal around it expands and allows the surfaces bonded by rust to come apart. 6. If the rear brakes were obtained from an EGT (or that generation). You can use a wire brush on a drill or similar tool to get most of the rust off of the parts. Having the complete rear disc assembly taken apart. Once the caliper swung free of the brake pads. To remove the dust shields. which may cost around $ 20. With a 14mm socket. Using a propane torch to focus heat only on the spindle while putting an impact gun on the bolt. To remove the hub. the e-brake cables will be attached to the calipers with a lock nut. This is a good time to check if the calipers are still in a usable condition. Remove the caliper. If the screws are not cooperating. and then hit them with the sledge. 8. An impact gun with at least 500 lb of torque is required. loosen the caliper bolt. 11. Using a 10mm socket. it is time toclean them up as they're still rusty. take a flathead screwdriver and carefully pry the grease cap from the spindle. This will be used as a spacer for the rear control arm. They should come off once they come loose. and set them aside for reuse. You will now be left with the spindle. and drilling the center out. Now that the calipers have been removed. 12. Then remove the retainer with a 32mm socket and an impact gun. Just make sure that they return the spindle. 14. This should allow the caliper to rotate on its hinge. The hub will slide right off the spindle. There are four of methods to removing the bolt. take a 14mm socket to the four bolts holding it to the spindle. It is best to wear a dust mask or respirator while cleaning them. until it is free from the caliper bracket.

Rear Brake Operating Lever 16. Remove the brake caliper bleeder screw and Brake Caliper Bleeder Screw Cap 12. Rear Disc Brake Caliper 10. 3. Caliper Bolt Dust Boot 9. 1.Ford Escort rear disc brake conversion . however be used as a core to purchase a rebuilt caliper. 6/1/2015 7:23 PM . Brake Connecting Link 8. Brake Adjuster Screw 13. but it is relatively inexpensive and not very difficult to rebuild them. Caliper Bolt 19. 2. Remove the screw plug.php/Ford_Escort_rear_disc_brake_conversion Caliper Inspection/Rebuild In order for the brake system to function properly. A caliper rebuild kit is available at most auto parts stores. It can. Piston Dust Seal 2.Mechanical Database 5 of 8 http://mechdb. Rear Disc Brake Adjuster Spindle 6. NAPA has a kit (part # 2735) that includes the boots and O-rings necessary to completely rebuilt one caliper. the calipers must be checked to make sure they are usable. Piston Seal 4. Rear Brake Operating Lever Seal 15. Snap Ring 5. Brake Caliper Bleeder Screw 11. Caliper Bolt Cover 18. Caliper Bolt Dust Boot If the cylinder walls of the caliper are pitted. Caliper diassembly 1. Rear Brake Operating Lever Spring 17. Pictured below is an exploded view of the rear brake caliper and its components. the caliper cannot be used. O-Ring 7. Piston 3. Screw Plug 14. Remove the caliper bolt dust boots. Rebuilding the calipers may not be entirely necessary.

To complete the installation. Discard the O-ring. Piston damage could result. 8. and discard the seal. EXCESSIVE PRESSURE CAN FORCE THE PISTON OUT OF THE CALIPER BORE WITH ENOUGH FORCE TO CAUSE PERSONAL INJURY. If the rear disc brake caliper bore is scored or corroded. Installation By now. 9. 7. and the brake connecting link. 6. WARNING: USE ONLY AS MUCH COMPRESSED AIR AS NECESSARY TO REMOVE THE PISTON.php/Ford_Escort_rear_disc_brake_conversion 4. When removing the piston it is necessary to cover the brake caliper bleeder screw hole and the brake adjuster screw hole. Remove the rear brake operating lever. if desired).Ford Escort rear disc brake conversion . Remove the snap ring. replace the rear disc brake caliper. Do not hone the cylinder bore. 10. you should have the major parts cleaned (and painted. NEVER ATTEMPT TO CATCH THE PISTON BY HAND AS IT COMES OUT OF THE BORE. CAUTION: Use a plastic or wooden pick to remove the piston seal from the rear disc brake caliper bore. 5.Mechanical Database 6 of 8 CAUTION: Do not use a screw driver or any other similar tool to pry the piston out of the bore. Remove the piston seal from the bore. Remove the rear brake operating lever seal. the O-ring. Place a block of wood between the piston and the rear disc brake caliper and remove the piston using compressed air. the following parts are required: 6/1/2015 7:23 PM . ready to go. A metal tool may scratch or nick the piston seal groove which could result in a leak. 11. Remove the rear brake operating lever spring. rear disc brake adjuster spindle. Turn the brake adjuster screw clockwise until the piston is loose enough to remove. Remove the piston dust seal. Pistons are not available for honed cylinder bores.

Do not tighten the nut just yet. Tighten all fasteners to spec (17mm Control arms: 64-86 lb/ft. 3. with the long bolt and nut. it's time to put the new brakes on. Tap a grease cap onto the hub. install them as well (Phillips #1 7-10 lb/ft). 6/1/2015 7:23 PM . If you did not assemble the brakes beforehand. Unclip the brake line from the strut. Depending on the condition of the parking brake cables. Mount the spindle on the control arms. 1. the concept with removing the drums is identical to the removal of discs (above). 21mm bolt head). Remove the trailing arm bolt (17mm). Be prepared to have to run somewhere. Stake the hub retainer with a chisel or screwdriver. this bolt can be hard to remove (17mm nut. you can also get matching parts for the front. and remove the brake line completely (10mm line wrench for both ends). Now. Again. as shown. 3. Loosely attach the trailing arm to the bottom of the spindle. Install the rotors. If you are going to purchase performance brakes for the rear.php/Ford_Escort_rear_disc_brake_conversion Rotors Brake Lines Brake Pads Brake Fluid These parts are readily available in OEM form at most auto parts stores. 2. Trailing Arm: 69-94 lb/ft. if you are doing this on the weekend. 2. pads and stainless lines in a variety of styles and colors (for rotors and lines). This is where the spacer is used. You may even require buying a replacement afterwards. install the dust shield to the spindle (14mm 34-44 lb/ft). Attach new brake lines to the hard lines on the car (10mm line wrench). Position the caliper bracket on the spindle and install the 2 bolts (14mm 34-44 lb/ft).Mechanical Database 7 of 8 http://mechdb. It goes between each rear control arm and the spindle. TRINet Motorsports carries performance rotors. or have the car sit. 1. 5. 3. Jack the spindle. in case you forgot something. 4. You can decide whether you assemble the rear disc setup on. The seemingly obvious first step is to find a nice flat place to raise and support the vehicle. except the cable on the drum side is connected slightly different. When you have the drum setup off. so that the control arms are parallel to the ground. If so. Struts 76-100 lb/ft). If you we able to salvage the screws. 4. they may need to be replaced. install a new hub rear axle wheel hub retainer using an impact wrench (32mm 130-174 lb/ft). and the dealer isn't open to get a bolt that got messed up.Techna-Fit 14mm 16-22 lb/ft) 5. 1. (OEM 12mm. Either way will work with the same results. 2. Therefore. The last part is removing the control arms from the spindle. These can also be ordered from your local auto parts store. they carry the same part number. Position the hub onto the spindle. Note that the brake lines are the same for the rear discs as they are for the front. The parking brake cables are removed the exact same way as above. or off the car. Install the brake pads and Escort rear disc brake conversion . or Ford dealership. Remove the struts from the spindle (17mm) 5. the part number from Ford is F7CZ-5Z997-AA. using a banjo bolt and a copper washer on each side. You may also want upgraded parts. Jack up the entire rear end and support the car with jack stands. You are now presented with another choice. 4. Loosely attach the spindle to the strut. Then attach the brake line to the caliper.

Make sure that the brake reservoir is full of fluid while bleeding the brakes. Apply the brakes gradually instead of slamming on them. then turn back the piston 1/3 turn. But before you go try stopping hard from 75 MPH. "tighten" the adjuster screw behind each caliper until the brake pads just touch the rotor. 8. 9. Attach the brake caliper bolt (10mm 33-43 lb/ft). you need to do one last thing . Repeat this step 15-20 times.Ford Escort rear disc brake conversion . Drive around a residential or business area where you can drive up to 25-30 MPH. Bleed the rear brakes. If you are putting new stainless lines on the front. and brake to about 10 MPH. Pivot the rear disc brake caliper over the brake pads. you can do regular driving but still take it easy on the rotors for another 10-20 miles. Adjust the parking brake lever. you should have a nice set of brakes on your car. Privacy policy About Mechanical Database Disclaimers Powered by MediaWiki Designed by Paul Gu 6/1/2015 7:23 PM . Start at the passenger rear. Also see Ford Escort & ZX2 section for the entire index of all Ford Escort and ZX2 related articles. Using the 4mm allen wrench. After doing that. 10. Replace the cap on the caliper bolt. and finally the driver front. then driver rear. using a 10mm deep well socket. Take your vehicle up to about 25 MPH. Break-in Procedure If all went well.break in those new rotors and pads. bleed them as well. 6.Mechanical Database 8 of 8 http://mechdb. the passenger front.