boot FORD MUSTANG 2003 User Guide

DESCRIPTION AND OPERATION
Front Disc Brake
Front Disc Brake Components
Disc Brake Caliper Components SECTION 206-
03: Front Disc Brake 2003 Mustang Workshop Manual Item Part Number Description
1 — Bleeder screw and bleeder screw cap assy
2 2N386 Caliper bolt
3 2B296 Guide pin
4 2A492 Guide pin boot
5 2B120 Disc brake caliper
6 2B164 Anti-
rattle spring 7 2B292 Front disc brake caliper anchor plate
8 385116-S2 Flow bolt
9 2078 Front brake hose Klj . 1 ba
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The front disc brake caliper (2B120):
zbolts to the front disc brake caliper anchor plate (2B292), which bolts to the front wheel spindle
(3105).
z is a pin slider, dual piston design.
The front brake discs (1125):
zare of a ventilated full- cast design, with non-directional cooling fins.
z are serviced with the disc brake caliper and front disc brake caliper anchor plate removed.
The front brake disc shield (2K005): Item Part Number Description
1 2B120 Disc brake caliper
2 2L126 Bleeder screw cap
3 2208 Bleeder screw
4 2B164 Anti-
rattle spring 5 2196 Caliper piston
6 2B115 Piston seal
7 2207 Piston dust boot
8 2L200 Pad slipper
9 2B292 Front disc brake caliper anchor plate
10 2001 Brake pads
11 2A492 Guide pin boot
12 2B296 Guide pin
13 2N386 Caliper bolt Klj . 2 ba
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6.
CAUTION: Do not pry in caliper sight hole to retract pistons as this can damage the
pistons and boots.
CAUTION: When removing the disc brake caliper (2B120), never allow it to hang
from the brake hose. Provide a suitable support.
Lift the caliper off the anchor plate (2B292).
7. Remove the pads and the pad slippers. 1. Remove the pads and verify thickness.
2. Remove and discard slippers. Klj . 2 ba
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8. Measure the front brake disc thickness.
zInstall a new front brake disc (1125) if not within specification.
9. Inspect the disc brake caliper. zIf leaks or damaged boots are found, disassembly is required. For additional information,
refer to Caliper in this section. Klj . 3 ba
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10. Inspect the front disc brake anchor plate assembly.
zCheck the guide pin boots for damage.
z Check the guide pins for binding and damage.
z Worn or damaged pins should be installed new.
Installation 1. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the
pad lining material. Do not install contaminated pads.
NOTE: Install all hardware supplied with pad kits.
Install the pads. 1. Install the new pad slippers.
2. Install the pads. Klj . 4 ba
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2.
NOTE: Use a wood block or used pad to protect pistons and boots.
Compress the caliper pistons (2196).
3. Make sure the anti- rattle spring is correctly positioned in the caliper. Klj . 5 ba
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10. Inspect the disc brake caliper.
zIf leaks or damaged boots are found, disassembly is required. For additional information,
refer to Caliper in this section.
11. NOTE: Use a wood block or used pad to protect pistons and boots. Compress the caliper pistons (2196). Klj . 3 ba
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5. Lift the caliper off the anchor plate (2B292).
6. Inspect the disc brake caliper.
zIf leaks or damaged boots are found, disassembly is required. For additional information,
refer to Caliper in this section.
Installation 1. Make sure the anti- rattle spring is correctly positioned in the caliper. Klj . 2 ba
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2.
CAUTION: Make sure guide pin boots are correctly seated or damage to guide pins
can occur.
Install the disc brake caliper. 1. Hold the guide pins stationary.
2. Install the caliper bolts.
3. NOTE: Use new copper washers.
Install the front brake hose. Klj . 3 ba
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DISASSEMBLY AND ASSEMBLY
Caliper
Disassembly
1. Remove the disc brake caliper (2B120). For additional information, refer to Caliper in this
section.
2. Drain the remaining brake fluid from disc brake caliper.
3. Apply low air pressure to the fluid port in the disc brake caliper. 1. Place a block of wood between the caliper bridge and the caliper pistons (2196).
2. Apply low air pressure to the fluid port in the disc brake caliper and force out the caliper pistons to the block of wood.
4. Remove the caliper pistons. 1. Remove the block of wood.
2. Remove the caliper pistons.
5. Remove and discard the piston seals and boots.
SECTION 206-
03: Front Disc Brake 2003 Mustang Workshop Manual Klj . 1 ba
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