Brake System - General Information: Other Ford Explorer V

Material(s)

MATERIAL(S)

Brake Pads

Note. It is not required to install new brake pads when the brake discs are machined.

1. Inspect the brake pad friction material for contamination. If the friction material shows evidence of contamination, install new brake pads. For the front brake pads, REFER to «BRAKE PADS - FRONT»(ref-517543-S32013098012012121200000) , or For the rear brake pads, REFER to «BRAKE PADS - REAR»(ref-517553-S09388031992012121200000) .
2. Inspect and measure the thickness of the brake pad friction material. REFER to «General Specifications»(ref-517551-S04646352332012121200000) . Minor surface cracks do not require pad replacement, however, if there are missing chunks or cracks in the lining through to the backing plate, install new brake pads. For the front brake pads, REFER to «BRAKE PADS - FRONT»(ref-517543-S32013098012012121200000) , or For the rear brake pads, REFER to «BRAKE PADS - REAR»(ref-517553-S09388031992012121200000) . If the thickness of the friction material is less than the specified thickness, install new brake pads. For the front brake pads, REFER to «BRAKE PADS - FRONT»(ref-517543-S32013098012012121200000) , or For the rear brake pads, REFER to «BRAKE PADS - REAR»(ref-517553-S09388031992012121200000) . If the friction material shows taper wear that is not within specifications, install new brake pads and verify the caliper guide pins are functioning correctly. REFER to «Brake System Inspection»(ref-517551-S29218250352012121200000) .

Brake Disc

Note. Using an impact tool without a torque socket leads to unevenly tightened wheel nuts. This causes brake disc on-vehicle lateral runout and brake roughness.

1. Inspect the brake discs and measure the brake disc thickness. Record the measurement, REFER to «General Specifications»(ref-517551-S04646352332012121200000) . If the brake disc is cracked or otherwise damaged, install a new brake disc. For Front disc brakes, REFER to «FRONT DISC BRAKE SYSTEM»(ref-517543) or Rear disc brakes, REFER to «REAR DISC BRAKE SYSTEM»(ref-517553) . If the measurement is below the minimum thickness specification, install a new brake disc. For Front disc brakes, REFER to «FRONT DISC BRAKE SYSTEM»(ref-517543) or Rear disc brakes, REFER to «REAR DISC BRAKE SYSTEM»(ref-517553) . If the diagnosis has revealed vibration in the steering wheel, seat or pedal while braking that varies with vehicle speed, machine the brake disc. Heavily scored brake discs, similar to that caused by pads worn down to the backing plate, should also be machined. In order to machine, discs must be above the minimum thickness specification. REFER to «General Specifications»(ref-517551-S04646352332012121200000) and REFER to «Brake Disc Machining»(ref-517551-S35887341932012121200000) .

Brake Caliper

1. Inspect the brake calipers for leaks, damage to seals and piston corrosion or binding. If the brake caliper is leaking or otherwise damaged, install a new brake caliper. For front brake calipers, REFER to «BRAKE CALIPER - FRONT»(ref-517543-S01390948202012121200000) , or For rear brake calipers, REFER to «BRAKE CALIPER - REAR»(ref-517553-S04239896402012121200000) .

Brake Caliper Guide Pins

1. The guide pins should slide with a reasonable amount of hand force. If the brake pads show taper wear or the guide pins are difficult to move, carry out the following steps. Disassemble the brake caliper guide pins and inspect the guide pins and guide pin bores for wear, damage and corrosion. If bore is worn or damaged, replace the damaged component. Use a wire brush, rolled-up sandpaper or emery cloth to remove all corrosion and foreign material from the caliper guide pin bores. Clean any remaining foreign material from the bores with brake parts cleaner and compressed air. Assemble the caliper seals, boots and guide pins. Use an ample amount of the specified grease to lubricate the bores and guide pins. Inspect the brake pads. REFER to «Brake System Inspection»(ref-517551-S29218250352012121200000) .

Brake Flexible Hose

Note. Never use copper tubing. It is subject to fatigue, cracking and corrosion, which may result in brake tube failure.

Note. Double-wall steel tubing is used throughout the brake hydraulic system. All brake tube fittings must be correctly double flared to provide strong, leakproof connections. When bending tubing to fit the underbody or rear axle contours, be careful not to kink or crack the tube.

1. Inspect brake tubes for corrosion, cracks, leaks or any other signs of damage. If a section of the brake tube is damaged, replace the entire section with a new tube of the same type, size, shape and length. When installing the hydraulic brake tubing, hoses or connectors, tighten all connections to specifications. After installation, bleed the brake system. REFER to «Brake System Bleeding»(ref-517551-S37975793432012121200000) .
2. Inspect the brake flexible hoses for cracks, leaks and swelling during brake application or any other signs of damage. Install a new brake flexible hose if the hose shows signs of softening, cracking or other damage. For the front brake flexible hose, REFER to «BRAKE FLEXIBLE HOSE - FRONT»(ref-517543-S15609391112012121200000) , or For the rear brake flexible hose, REFER to «BRAKE FLEXIBLE HOSE - REAR»(ref-517553-S32597431432012121200000) .

Brake Master Cylinder

Note. During normal operation of the brake master cylinder, the fluid level in the brake master cylinder reservoir falls during brake application and rises during release. The returning brake fluid creates a slight turbulence in the master cylinder reservoir. This is a normal condition and indicates that the compensator ports are not clogged. Clogged compensator ports may cause the brakes to hang up or not fully release. The net fluid level (such as after brake application and release) will remain unchanged. Fluid level will decrease with pad wear.

Note. A trace of brake fluid will exist on the booster shell below the master cylinder mounting flange. This results from the normal lubricating action of the master cylinder bore and seal.

1. Inspect the brake master cylinder for fluid leaks. Install a new master cylinder or brake fluid reservoir if signs of excessive leaking are present. REFER to «BRAKE MASTER CYLINDER»(ref-517554-S37383011382012121200000) . To check for correct brake master cylinder operation, REFER to «COMPONENT TEST(S)»(ref-517551-S17224832492012121200000) .

Brake Booster

1. Inspect the brake booster for excessive corrosion or damage. Inspect the vacuum hoses for leaks and kinks. Install a new brake booster if signs of excessive corrosion or damage is found. REFER to «BRAKE BOOSTER»(ref-517556-S12538183072012121200000) . Repair or replace vacuum hoses as necessary. To check for correct brake booster operation, REFER to «Brake Booster»(ref-517551-S13978425962012121200000) .

General Procedure

Note. Do not use a bench lathe to machine the brake discs. Use an on-vehicle brake lathe only. Read the entire operating manual and/or view the video shipped with the lathe before installing, operating or repairing the lathe.

Note. An on-vehicle brake lathe with an automatic runout adjustment feature is preferred. However, if the lathe is not self-adjusting, the lathe oscillation must be adjusted using a dial indicator. The total indicated runout target is 0 mm (0 in). The maximum indicated runout should be no more than 0.05 mm (0.002 in). If the runout adjustment (automatic or manual) is carried out correctly prior to machining, then the final brake disc runout will be within specification and a runout measurement is not necessary after machining.

Note. Lateral runout and disc thickness variation measurements are not required because correct adjustment of the on-vehicle brake lathe will make sure that these dimensions are within specification.

1. Remove the wheel and tire. REFER to «WHEEL AND TIRE»(ref-517542) .
2. NOTE: Do not allow the caliper to hang from the brake hose or damage to the hose may occur. Remove the bolts and position the brake caliper or brake caliper and anchor plate assembly aside, as required. Support the brake caliper using mechanic's wire.
3. Install the hub adapter using: four wheel nuts on a 4-stud wheel hub. five wheel nuts on a 5-stud wheel hub. six wheel nuts on a 6-stud wheel hub. four wheel nuts on a 7- or 8-stud wheel hub. five wheel nuts on a 10-stud wheel hub.
4. Install the cutting lathe.
5. If the lathe is not self-adjusting, adjust the lathe oscillation using a dial indicator. The total indicated runout target is 0 mm (0 in). The maximum indicated runout should be no more than 0.05 mm (0.002 in).
6. Center the cutting head, adjust the cutting bits and install the chip deflector/silencer.
7. NOTE: The depth of the cut should be between 0.1 mm (0.0039 in) and 0.4 mm (0.0157 in). Lighter cuts will cause the bit to heat up and wear faster. Heavier cuts will cause poor brake disc surface finish. Machine the brake disc.
8. Remove the lathe and the silencer.
9. Remove the wheel nuts and hub adapter.
10. Remove the metal shavings.
11. Measure the brake disc thickness. If the measurement is below the minimum specification, install a new brake disc. For Front disc brakes, REFER to «FRONT DISC BRAKE SYSTEM»(ref-517543) or Rear disc brakes, REFER to «REAR DISC BRAKE SYSTEM»(ref-517553) .
12. NOTE: It is not required to install new brake pads if friction material is within specifications. For additional information, refer to «General Specifications»(ref-517551-S04646352332012121200000) . Position the brake caliper or brake caliper and anchor plate assembly. Install the bolts. For fastener torque specifications, For Front disc brakes, REFER to «TORQUE SPECIFICATIONS - FRONT»(ref-517543-S18664120592012121200000) , or For Rear disc brakes, REFER to «TORQUE SPECIFICATIONS - REAR»(ref-517553-S18819586242012121200000) .
13. Install the wheel and tire. REFER to «WHEEL AND TIRE»(ref-517542) .

Note. Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.

Note. When a new brake master cylinder has been installed or the system has been emptied, or partially emptied, it should be primed to prevent air from entering the system.

Scheme 4

Scheme 5

1. Disconnect the brake tubes from the master cylinder.
2. Install short brake tubes onto the primary and secondary ports with the ends submerged in the brake master cylinder reservoir.
3. Fill the brake master cylinder reservoir with clean, specified brake fluid.
4. Have an assistant pump the brake pedal until clear fluid flows from the brake tubes without air bubbles.
5. Remove the short brake tubes, and install the master cylinder brake tubes.
6. Bleed the brake system. REFER to «Brake System Bleeding»(ref-517551-S37975793432012121200000) .

Note. Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.

Scheme 6

1. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was disconnected. Remove the brake caliper bleeder screw cap and place a box-end wrench on the bleeder screw. Attach a rubber drain hose to the bleeder screw and submerge the free end of the hose in a container partially filled with clean, specified brake fluid.
2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal.
3. NOTE: Due to the complexity of the fluid path within the rear integral parking brake calipers, it is necessary to press and release the parking brake during the bleed procedure. Loosen the bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the bleeder screw. If bleeding a rear brake caliper, press and release the parking brake 5 times. Repeat until clear, bubble-free fluid comes out. Refill the brake master cylinder reservoir as necessary.
4. Tighten the brake caliper bleeder screw, remove the rubber hose and install the bleeder screw cap. Tighten the front brake caliper bleeder screws to specification. REFER to «Torque Specifications»(ref-517551-S28784514542012121200000) . Tighten the rear brake caliper bleeder screws to specification. REFER to «Torque Specifications»(ref-517551-S28784514542012121200000) .

Pressure Bleeding

Note. Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.

Note. Pressure bleeding the brake system is preferred to manual bleeding.

Note. The HCU bleeding procedure must be carried out if the HCU or any components upstream of the HCU are installed new.

Scheme 7

Scheme 8

1. Clean all the dirt from around the brake fluid reservoir cap and remove the cap. Fill the brake master cylinder reservoir with clean, specified brake fluid.
2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter. Install the bleeder adapter to the brake master cylinder reservoir and attach the bleeder tank hose to the fitting on the adapter.
3. NOTE: Make sure the bleeder tank contains enough specified brake fluid to complete the bleeding operation. Open the valve on the bleeder tank. Apply 207 kPa (30.02 psi)-345 kPa (50.04 psi) to the brake system.
4. Remove the RH rear bleeder cap and place a box-end wrench on the bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified brake fluid.
5. NOTE: Due to the complexity of the fluid path within the rear integral parking brake calipers, it is necessary to press and release the parking brake during the bleed procedure. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then tighten the RH rear bleeder screw. Press and release the parking brake 5 times. Repeat until clear, bubble-free fluid comes out.
6. Tighten the RH rear bleeder screw to specification. REFER to «Torque Specifications»(ref-517551-S28784514542012121200000) . Remove the rubber hose and install the bleeder screw cap.
7. Repeat Steps 5 and 6 for the LH rear brake caliper.
8. Continue bleeding the front of the system, going in order from the RH front brake caliper and then to the LH front brake caliper. Tighten the front brake caliper bleeder screws to specification. REFER to «Torque Specifications»(ref-517551-S28784514542012121200000) .
9. Close the bleeder tank valve and release the pressure. Remove the tank hose from the adapter and remove the adapter. Fill the reservoir with clean, specified brake fluid and install the reservoir cap.

Manual Bleeding

Note. Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.

Note. Pressure bleeding the brake system is preferred to manual bleeding.

Note. The HCU bleeding procedure must be carried out if the HCU or any components upstream of the HCU are installed new.

Scheme 9

1. Clean all the dirt from around the brake fluid reservoir cap and remove the cap. Fill the brake master cylinder reservoir with clean, specified brake fluid.
2. Remove the RH rear bleeder cap and place a box-end wrench on the bleeder screw. Attach a rubber drain tube to the RH rear bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified brake fluid.
3. Have an assistant hold firm pressure on the brake pedal.
4. NOTE: Due to the complexity of the fluid path within the rear integral parking brake calipers, it is necessary to press and release the parking brake during the bleed procedure. Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH rear bleeder screw. Press and release the parking brake 5 times. Repeat until clear, bubble-free fluid comes out. Refill the brake master cylinder reservoir as necessary.
5. Tighten the RH rear bleeder screw to specification. REFER to «Torque Specifications»(ref-517551-S28784514542012121200000) . Remove the rubber hose and install the bleeder screw cap.
6. Repeat Steps 2 through 5 for the LH rear brake caliper.
7. Remove the RH front bleeder cap and place a box-end wrench on the bleeder screw. Attach a rubber drain tube to the RH front bleeder screw and submerge the free end of the tube in a container partially filled with clean, specified brake fluid.
8. Have an assistant hold firm pressure on the brake pedal.
9. Loosen the RH front bleeder screw until a stream of brake fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the RH front bleeder screw. Repeat until clear, bubble-free fluid comes out. Refill the brake master cylinder reservoir as necessary.
10. Tighten the RH front bleeder screw to specification. REFER to «Torque Specifications»(ref-517551-S28784514542012121200000) . Remove the rubber hose and install the bleeder screw cap.
11. Repeat Steps 7 through 10 for the LH front brake caliper bleeder screw.

Hydraulic Control Unit (HCU) Bleeding

Note. Pressure bleeding the brake system is preferred to manual bleeding.

1. Follow the pressure bleeding or manual bleeding procedure steps to bleed the system.
2. Connect the scan tool and follow the ABS Service Bleed instructions.
3. Repeat the pressure bleeding or manual bleeding procedure steps to bleed the system.