Section 06-03: Brakes, Front Disc
1993 Mustang Workshop Manual
REMOVAL AND INSTALLATION

Caliper Assembly

Tools Required:

 

Removal

  1. Raise vehicle on hoist. Refer to Section 00-02.
  1. Remove wheel and tire assembly from hub. Use care to avoid damage to, or interference with bleeder screw fitting during removal.
  1. Disconnect the flexible brake hose from the caliper. Disconnect the hose, and loosen the tube fitting that connects the hose to the brake tube at the bracket on the frame. Plug the brake tube. Remove the horseshoe-shaped retaining clip from the hose and bracket; disengage the hose from the bracket; then unscrew the entire hose assembly from the caliper. Mark the RH and LH caliper assemblies with chalk prior to removal from the vehicle, so they can be positioned correctly during installation.
  1. Remove the caliper locating pins.

    NOTE: Mustang 2.3L vehicles require the use of a Torx® Drive Bit D79P-2100-T50 or equivalent.

  1. Lift the caliper from the integral spindle/anchor plate and rotor.
 

Installation

  1. Install the caliper assembly over the rotor with the outer brake shoe against the rotor's braking surface. This prevents pinching the piston boot between the inner brake shoe and the piston. Make sure the correct caliper is installed on the correct anchor plate according to the way they were marked during disassembly.
  1. Ensure the locating pins are free of oil, grease and dirt. Lubricate the rubber insulators with 4-8 grams (14-28 oz.) of Ford Silicone Dielectric Compound D7AZ-19A331-A (ESE-M1C171-A) or equivalent.
  1. Install new locating pins on Mustang 2.3L (On Mustang 5.0L the locating pins can be reused). Ensure locating pins are free from oil, grease, and dirt. The locating pins are installed through the outer shoe then into the spindle/anchor plate assembly, and finally inserted through the insulators on the caliper assembly. The locating pins must be hand inserted, then they must be hand threaded to start them into the spindle/anchor plate assembly before the pins are tightened. Ensure the rubber insulators are not damaged during pin insertion.
  1. On Mustang 5.0L vehicles, tighten the caliper locating pins to 61-88 Nm (45-65 lb-ft). On Mustang 2.3L vehicles, use a Torx® Drive Bit D79P-2100-T50 or equivalent. Tighten to 61-88 Nm (45-65 lb-ft).
  1. On Mustang 2.3L thread the flexible brake hose into its fitting on the caliper. This is a special self-sealing fitting that does not require a gasket. Tighten hose fitting to 27-41 Nm (20-30 lb-ft).



    NOTE: When hose is correctly tightened there should be one or two threads of the fitting still showing at the caliper. It is not necessary for the hose fitting to be flush with the caliper for sealing; therefore, do not overtighten.






    Item Part Number Description
    1 2263 Assy RH
    2264 Assy LH     		Brake Tube
    2 — Sidemember
    3 2078 Brake Line Assy (2 Req'd)
    4A N802191-S2 Bolt (2 Req'd)
    5B — Nut
    6 2B118-9 Caliper Assy
    7 386493-S100 Clip (2 Req'd)
    8 2082 RH
    2A056 LH     		Bracket
    9 2078 Assy RH
    2B557 Assy LH     		Brakeline
    10 2B198-9 Caliper Assy
    11 2B118-9 Assy
    12 388949-S Washer (4 Req'd)
    13C N801052-S100 Bolt (2 Req'd)
    14 — Brake Hose
    15 — Collar
    16 — Caliper Inlet
    17 — Brake Hose Seals Here
    A Tighten to 11-16 Nm (8-12 Lb-Ft)
    B Tighten to 27-41 Nm (20-30 Lb-Ft)
    C Tighten to 40-60 Nm (26-44 Lb-Ft)

    On Mustang 5.0L, install the flexible brake hose to the caliper, use a hollow bolt and two new sealing washers. Tighten hose fitting to 40-60 Nm (26-44 lb-ft).

  1. Position the upper end of the flexible brake hose in its bracket, and install the retaining clip. Do not twist the hose. Remove the plug from the brake tube. Connect the brake tube to the hose with the tube fitting nut, and tighten to 14-24 Nm (10-18 lb-ft).
  1. Bleed the brake system, and centralize the brake pressure differential valve.
  1. Fill the master cylinder as required to within 6.35mm (1/4 inch) of the top of the reservoir.
  1. Install the wheel and tire assembly. Tighten wheel lug nuts to 115-142 Nm (85-105 lb-ft).
  1. Lower vehicle.
  1. To position the brake linings, apply the brake pedal several times prior to moving the vehicle.
  1. Road test vehicle.