1996 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...

Normal Hydro-Boost units will produce certain noises that current technology cannot correct. These noises occur when brake pedal is manipulated in a manner not associated with everyday braking habits. Normal operating noise can be a hissing, clunk, click or a chatter.

If above normal pedal efforts are applied, the Hydro-Boost unit will emit hissing noises. These noises will be particularly noticeable with the vehicle motionless and will increase in intensity as pedal efforts increase and system operating temperatures increase. Loud hissing noises at or below normal pedal effo...

Refer to Figs. and for ABS wiring circuits when performing a thorough visual inspection of the anti-lock...

Bleed primary and secondary hydraulic brake systems separately, bleeding the longest line first on each system. Do not allow reservoir to run dry during bleeding operation. Never reuse fluid that has been drained from the hydraulic system.

• Loosen master cylinder to hydraulic line nuts and wrap shop cloths around tubing below fitting to absorb escaping brake fluid.
• Depress brake pedal slowly forcing air trapped in master cylinder out at fitting.
• Hold pedal down and tighten fittings, then release brake pedal. Releasing brake pedal before fittings are tightened will allow air to en...

Accessing Diagnostic Trouble Codes

Diagnostic trouble codes can be retrieved from the ABS control module in the following manner:

• Connect New Generation Star (NGS) Tester tool No. 007-00500, or equivalent, to 16-pin connector located under steering column.
• Turn tester on and follow menus to perform ABS diagnostic trouble code retrieval.
• Record all diagnostic trouble codes. System Pass indicates no diagnostic trouble codes are stored.
• Refer to "Diagnostic Chart Tests" for appropriate test(s) to be performed.

Diagnostic Trouble Code Interpretation

When specific diagnostic trouble codes...

The four wheel anti-lock brake system prevents wheel lockup by automatically modulating brake pressure during an emergency stop. The system uses an ABS control module and a hydraulic control unit (HCU) to control both front and rear brakes separately. When the brakes are applied, fluid is forced from the brake master cylinder to the hydraulic control unit (HCU), then to the wheels. One circuit of the master cylinder feeds the left front and right rear brakes. The other circuit feeds the right front and left rear brakes. If the ABS control module senses that a wheel is about to lock,...