1995 Ford Windstar Brake Service (ONLINE REPAIR MANUALS)

Aerostar, Explorer & Ranger

• Remove caliper as described under "Caliper Service," leaving brake hose connected.
• Secure caliper with wire so that caliper is not hanging with weight on brake hose.
• Compress anti-rattle clip, then remove inner pad from caliper.
• Press each ear of outer pad away from caliper, slide torque buttons out of retention notches and slide pad off caliper.
• Reverse procedure to install, noting the following:
• Use an eight inch C-clamp and a worn inner pad or block of wood to bottom out caliper piston in bore.
• Install new anti-rattle clip on lower end of inner pad.
• Refill...

Brake System Bleed

Refer to "Hydraulic Brake Systems" for brake bleeding procedure.

Component Replacement

Hydraulic Control Unit (HCU)

• Disconnect battery ground cable.
• Disconnect 24-pin connector from ABS control module.
• Disconnect 2-pin power and ground connector from ABS control module.
• Remove two tubes from inlet ports and four tubes from outlet ports of HCU.
• Remove three attaching bolts retaining EHCU assembly to mounting bracket, then lower EHCU assembly down and out of engine compartment.
• Separate HCU from ABS control module by removing four torx head screws and disconnecting pump mot...

Replace

Aerostar, Explorer & Ranger

• Remove and discard a portion of brake fluid from master cylinder.
• Raise and support vehicle, then remove wheel and tire assembly.
• Use an eight inch C-clamp to move piston back into its bore as follows:
• Place head of C-clamp against caliper and screw end of C-clamp against outer pad below spring clip.
• Tighten C-clamp until torque buttons just clear caliper (approximately 1/8 inch). Remove C-clamp.
• Clean excess dirt from around pin tabs, then use caliper pin remover tool No. D89T-2196-A or equivalent and light hammer to drive caliper pin from caliper a...

Aerostar

Removal

• Disconnect battery ground cable.
• Remove sufficient brake fluid from master cylinder reservoir.
• Raise and support vehicle, then remove tire and wheel assembly.
• Remove disc brake caliper as outlined in "Caliper Service".
• On 2WD models, remove hub grease cap, cotter pin, nut retainer, hub spindle nut and front outer wheel bearing washer, then remove outer wheel bearing.
• On all models, remove front disc brake hub and rotor.
• On 4WD models, remove hub as outlined under "Halfshaft, Replace," in the "All Wheel Drive System" section.

Installation

• On 2WD models, install front disc brak...

Removal

• Raise and support vehicle, then remove wheel and tire assembly.
• Remove brake drum. If brake drum will not come off, remove rubber plug from adjuster hole and insert a screwdriver and brake adjustment tool No. D81L-1103-C, or equivalent, to disengage brake shoe adjusting lever and loosen brake adjuster screw .
• Disconnect parking brake cable from parking brake lever, then remove brake shoe hold-down springs and pins, Fig. .
• Remove upper retracting spring, then the lower retracting spring.
• Remove brake shoes from backing plate.
• Remove parking brake lever clip and washer, then the p...

Brake Linings

Remove both front wheels and inspect the brake discs, calipers and linings. (Wheel bearings should be inspected at this time and repacked if necessary).

Do not get any oil or grease on the linings. It is recommended that both front wheel sets be replaced whenever a respective shoe and lining is worn or damaged. Inspect and, if necessary, replace rear brake linings also.

If the caliper is cracked or fluid leakage through the casting is evident, it must be replaced as a unit.

Brake Roughness

The most common cause of brake chatter on disc brakes is a variation in thickness of ...