Brake Lining

Removal

1. Remove the master cylinder cap. Check fluid level in the primary (large) reservoir. Remove brake fluid until the reservoir is half full. Discard this fluid.

2. Raise vehicle on hoist. Refer to Section 00-02.

3. Remove the wheel and tire assembly from the hub. Be careful to avoid damage to, or interference with the caliper splash shield or bleeder screw fitting.

4. Remove the caliper locating pins.

5. Lift the caliper assembly from the integral spindle/ anchor plate and rotor. Remove the outer shoe from the caliper assembly.
   
   
   
   
   

   Item	Part Number	Description
   1	2B118 RH 2B119 LH	Caliper Assy (1 Req'd)
   2A	2B296	Caliper Locating Pin (4 Req'd)
   3	1190	Grease Retainer (2 Req'd)
   4	1201	Inner Bearing Assy (2 Req'd)
   5	1K002	Hub and Rotor Assy
   6	386485-S	Washer (2 Req'd)
   7	62045-S	Cotter Pin (2 Req'd)
   8	1131	Dust Cap (2 Req'd)
   9	385630-S5	Nut Retainer (2 Req'd)
   10	38340-S100	Adjusting Nut (2 Req'd)
   11	1216	Outer Bearing Assy (2 Req'd)
   12B	56518-S100	Bolt
   13	2K004 RH 2K005 LH	Splash Shield (1 Req'd)
   14	N800191-S	Gasket (2 Req'd)
   15	3107 RH 3108 LH	Combination Spindle and Anchor Plate (1 Req'd)
   16	2K004-5	RH Splash Shield
   A		Tighten to 61-88 Nm (45-65 Lb-In)
   B		Tighten to 13-20 Nm (108-166 Lb-In)

6. Remove the inner shoe and lining assembly. Pull shoe straight out of piston. This could require a force as great as 89-133 N (20-30 lb). Inspect both rotor braking surfaces. Minor scoring or buildup of lining material does not require machining or replacement of rotor.
   
   
   
   
   

   Item	Part Number	Description
   1	3108 LH 3107 RH	Spindle/Anchor Plate
   2	2B119 Assy LH 2B118 Assy RH	Caliper Assy
   3A	2B296	Combination Caliper Locating and Attaching Pin (4 Req'd)
   4	1190	Grease Retainer (2 Req'd)
   5	1201	Inner Bearing (2 Req'd)
   6	1K002	Hub and Rotor Assy (2 Req'd)
   7	386485-S	Washer (2 Req'd)
   8	383840-S100	Adjusting Nut
   9	385630-S	Nut Retainer (2 Req'd)
   10	72045-S	Cotter Pin (2 Req'd)
   11	1131	Dust Cap (2 Req'd)
   12	1216	Outer Bearing Assy (2 Req'd)
   13B	56518-S100	Bolt (6 Req'd)
   14	2K005 LH 2K004 RH	Splash Shield
   15	N800191-S	Gasket (2 Req'd)
   A		Tighten to 61-88 Nm (45-65 Lb-Ft)
   B		Tighten to 12-19 Nm (9-14 Lb-Ft)

7. Suspend the caliper inside the fender housing with a wire hooked through the outer leg hole of the caliper. Be careful not to damage the caliper or stretch the brake hose.

8. Remove and discard the caliper locating insulators. These parts must not be reused.

Installation

1. Use a 10cm (4 inch) C-clamp and a wood block 7cm (2-3/4 inch) x 2.5cm (1 inch) and approximately 19mm (3/4 inch) thick to seat the caliper hydraulic piston in its bore. This must be done to provide clearance for the caliper assembly to fit over the rotor when installed. Remove the C-clamp from the caliper (the caliper piston will remain seated in its bore).

2. Install new locating pins on Mustang 2.3L (on Mustang 5.0L, the locating pins can be reused). Install new locating pin insulators in the caliper housing. Do not use sharp-edged tool to insert insulators in the caliper housing.

   Lubricate the rubber insulators with Silicone Dielectric Compound D7AZ-19A331-A (ESE-M1C171-A) or equivalent.

   Verify that both insulator flanges straddle the housing holes. The illustration shows proper insulator installation and how to fabricate an installation tool.
   
   
   
   

3. Install the correct inner shoe and lining assembly in the caliper piston. The inner shoes are marked LH or RH and must be installed in the proper caliper. Also, care should be taken not to bend the anti-rattle clips too far in the piston because distortion and rattles can result.

   Inner shoe installation is accomplished by holding each end of the shoe, making sure it is square with the piston, and pushing the shoe in firmly until the clip snaps in position. Do not allow shoe or clip tangs to cock during installation to avoid bending clip.

4. Install the correct outer brake shoe and lining assembly (RH/LH), making sure that the clip is properly seated. The outer shoe can be identified as RH or LH by the wear indicator which must always be installed toward the front of the vehicle or by a LH or RH mark.

5. Install the wheel and tire assembly. Tighten wheel lug nuts to 115-142 Nm (85-105 lb-ft).

6. Lower vehicle.

7. Pump the brake pedal prior to moving the vehicle to position the brake linings. Refill the master cylinder.

8. Road test the vehicle.