206-03-1 Front Disc Brake 206-03-1

REMOVAL AND INSTALLATION

Disc 4x2 vehicles

Removal 4. NOTE: Match-mark the brake disc and hub

(1102).
All vehicles Remove the brake disc and hub as follows:
1 Remove the hub grease cap (1131).
1. Remove the front disc brake caliper anchor 2 Remove the cotter pin.
plate (2B292). For additional information, refer
to Brake Caliper Anchor Plate in this section. 3 Remove the nut retainer.
4 Remove the spindle nut.
4x4 vehicles
5 Remove the front wheel outer bearing
retainer washer (1195).
2. NOTE: Match-mark the brake disc (1125) and
6 Remove the outer front wheel bearing
hub (1104).
(1216).
Remove the brake disc.
7 Remove the brake disc and hub.
3. CAUTION: Use a hub-mount brake
lathe if necessary to machine the brake disc.
Measure the brake disc and resurface as
necessary.
Install a new brake disc if beyond specification.

5. Remove the wheel hub grease seal (1190) and

wheel bearing.
1 Remove the wheel hub grease seal.
2 Remove the wheel bearing.

Copyright  2003, Ford Motor Company

Last updated: 06/24/2003 2004 Explorer Sport Trac, 9/2003
206-03-2 Front Disc Brake 206-03-2
REMOVAL AND INSTALLATION (Continued)
6. CAUTION: Use a hub-mount brake
lathe if necessary to machine the brake disc.
Measure the brake disc, and resurface as
necessary. Install a new brake disc if beyond
specification.

3. Lubricate the front wheel bearings.

• Use Premium Long-Life Grease XG-1-C or
-K or equivalent meeting Ford specification
ESA-M1C75-B.

4. Install a new wheel hub grease seal.

Installation 1 Install the inner front wheel bearing.
2 Install a new wheel hub grease seal.
4x4 vehicles

1. Position the brake disc to the wheel hub.

• Use Metal Brake Parts Cleaner PM-4 or
equivalent to clean the brake disc.
• Using match-marks, mount the brake disc on
the hub.
• Apply High Temperature Nickel Anti-Seize
Lubricant F6AZ-9L494-AA or equivalent
meeting Ford specification ESE-M12A4-A
to the hub mounting surface to prevent
future corrosion.

4x2 vehicles

2. Thoroughly clean and inspect the front wheel

bearings and the brake disc and hub.
• Use Metal Brake Parts Cleaner PM-4 or
equivalent.

2004 Explorer Sport Trac, 9/2003

206-03-3 Front Disc Brake 206-03-3
REMOVAL AND INSTALLATION (Continued)
5. Install the brake disc and hub. 8. Tighten the spindle nut while rotating the brake
1 Position the brake disc and hub. disc and hub.
2 Install the outer front wheel bearing.
3 Install the front wheel outer bearing retainer
washer.
4 Install the spindle nut.

9. Install the following components:

1 Install the nut retainer.
2 Install the cotter pin.
3 Install the hub grease cap.
6. Tighten the spindle nut while rotating the brake
disc and hub.

7. Loosen the spindle nut.

2004 Explorer Sport Trac, 9/2003

206-03-4 Front Disc Brake 206-03-4
REMOVAL AND INSTALLATION (Continued)
All vehicles

10. Install the front disc brake caliper anchor plate.

For additional information, refer to Brake
Caliper Anchor Plate in this section.

2004 Explorer Sport Trac, 9/2003