Unable to install the outer pad - does the calibar slide on the two retaining bushings?? The new pads seem to be thicker and the auto parts store tell us we have the correct pads

Brake Pads Removal & Installation Front

To Remove:

1. Drain brake fluid to ½ full level in reservoir.
2. Remove the front wheels.
   
   
3. Remove the front brake caliper assembly.
4. Remove the 2 anti-squeal shims from each of the 2 brake pads.
5. Remove the wear indicator from each of the 2 brake pads.

To Install:
NOTE: When replacing worn pads, the anti-squeal shims must be replaced together with the pads.

1. Using a large C clamp or equivalent press piston into the caliper.
2. Apply disc brake grease to the inside of each anti-squeal shim.
3. Install the anti-squeal shims on each pad.
4. Install the pad wear indicator clip to the pads.
5. Install the pads with the pad wear indicator plate facing upward.
6. Install the brake caliper with the 2 mounting bolts. Torque the bolts 25 ft-lb (34 Nm).
7. Install the front wheels.
8. Fill the master cylinder with new clean brake fluid.
9. Pump the brake pedal several times to seat the brake pads.

Rear TMC made rear brake components

TMMK made rear brake components

To Remove:

1. Drain the brake fluid to ½ full level in reservoir.
2. Remove the rear wheels.
3. Remove the caliper slide pins.
4. Remove the caliper slide pin bushings (TMMK made) (Kentucky).
5. Remove the rear brake calipers.
6. Remove the 2 brake pads with the anti-squeal shims.
7. Remove the anti-squeal shims and pad wear indicators from brake pads.

To Install:

1. Using a large C clamp or equivalent press the piston into the caliper.
2. Coat both sides of the outer anti-squeal shim with pad grease.
3. Install anti-squeal shims to each pad.
4. Install wear indicators on the 2 brake pads.
5. Install the caliper slide pin bushings (TMMK made) (Kentucky).
6. Install the rear brake caliper with the slide pins. Torque the slide pins as follows:
   • TMC made (Japan): Torque the caliper slide pin 25 ft-lb (34.3 Nm)
   • TMMK made (Kentucky): Torque the caliper slide pin 34 ft-lb (47 Nm)
7. Fill the master cylinder with new clean brake fluid.
8. Pump the brake pedal several times to seat the brake pads.
9. Install the rear wheels.

Brake Rotor Removal & Installation Front To Remove:

1. Remove the front wheels.
2. Remove the front brake caliper assembly.
3. Remove the front brake pads.
4. Remove the 2 bolts and caliper mounting bracket.
5. Place match marks on the disc and axle hub.
6. Remove the front wheel disc.

To Install:

1. Align the match marks and install the front disc.
2. Install the brake caliper mounting bracket. Torque the bolts 79 ft-lb (107 Nm).
3. Install the brake caliper. Torque the bolts 25 ft-lb (34 Nm).
4. Install new gaskets and connect the brake hose to the caliper with the banjo fitting bolt. Torque the fitting bolt 22 ft-lb (29.4 Nm).
5. Fill the reservoir with brake fluid.
6. Bleed the brake system.
7. Install the front wheel.

Rear To Remove:

1. Remove the rear wheels.
2. Remove the brake caliper assembly.
3. Remove the brake pads.
4. Remove the 2 bolts and the caliper mounting bracket.
5. Place match marks on the disc and axle hub.
6. Remove the rear disc.

To Install:

1. Align the match marks and install the rear disc.
2. Install the rear brake caliper mounting bracket. Torque the bracket bolts as follows:
   • TMC made (Japan): Torque the bracket bolt 46 ft-lb (61.8 Nm)
   • TMMK made (Kentucky): Torque the bracket bolt 34 ft-lb (47 Nm)
3. Install the rear brake caliper with the slide pins. Torque the slide pins as follows:
   • TMC made (Japan): Torque the caliper slide pin 25 ft-lb (34.3 Nm)
   • TMMK made (Kentucky): Torque the caliper slide pin 32 ft-lb (43 Nm)
4. Install new gaskets and connect the brake hose to the caliper with the banjo fitting bolt. Torque the fitting bolt 22 ft-lb (29.4 Nm).
5. Fill the reservoir with brake fluid.
6. Bleed the brake system.
7. Install the rear wheel

Those are special calipers. The piston cannot be just compressed back into the caliper - it needs to be turned as it is compressed or you can ruin the caliper.There is a kit you can rent from AutoZone or many independent auto parts stores that will perform both functions at the same time.
Block fron wheels and raise vehicle passenger side. Remove wheel. The caliper is on the top rear side of the assembly you're looking at.There are 2 long bolts you'll need to remove to take the caliper off the vehicle. Don't remove the brake line or open the bleeder screw ( either of these moves will add to your work!! ) Insert a large flat blade screwdriver in between the rotor and outboard brake pad and pry away from the vehicle slightly to release the pads from the rotor. Slide caliper upwards and towards the back of the vehicle to separate from rotor. The pads will come in a full set ( all 4 pads for both side of the rear ) . Look at your replacement pads and determine if they have a retainer clip holding them in place or a compression clip. Remove outboard pad first then inboard. Match old pads to replacement pads. Inspect rotor for grooves and irregular surfaces - if any grooves or irregularity present, remove rotor and take to an auto parts store for refinishing.Compress caliper piston with kit and allow 5 minutes for pressure to bleed back into the master cylinder.install rotor if removed and wipe surfaces with brake clean. Install inboard then outboard pad and place caliper on rotor, then mount to vehicle. Install wheel, repeat procedure for drivers side, then PUMP BRAKE PEDAL 5 TIMES BEFORE TRYING TO DRIVE VEHICLE to set pads on rotors.

Removal & Installation

1. Siphon 2 / 3 of the brake fluid out of the master cylinder.
2. Mark the relationship of the wheel to the wheel stud for re-installation purposes. Remove the tire and wheel assembly.
3. Install 2 lug nuts to secure the rotor in place when the caliper is removed.
4. Install a large C-clamp over the top of the caliper housing and against the back of the outboard shoe. Slowly tighten the C-clamp until the caliper pistons are pushed into the caliper bore enough to slide the caliper assembly off the rotor. Use care not to tighten the C-clamp too far or the outboard shoe retaining spring will be deformed and require replacement.
5. Remove the caliper mounting bolts and remove the brake caliper from the mounting bracket.
6. DO NOT disconnect the brake hose from the caliper or allow the brake hose to support the weight of the caliper. Support the caliper on a piece of wire out of the way.
7. Remove the outer brake pad from the caliper using a suitable prying tool to lift the outboard shoe retaining spring so that it will clear the caliper center lug and pull the brake pad out of the caliper.
8. Remove the inner brake pad by unsnapping the shoe springs from the piston.
   

To install:

1. Clean all parts well. If the brake pads were worn so badly that the brake rotor is damaged, it must be replaced. Light scoring of the rotor surfaces not exceeding 0.060 inch (1.5mm) in depth is not harmful to brake operation and may result from normal use. Brake rotors may be refinished. Do not use a rotor that, after refinishing, will not meet the thickness specification cast in the rotor. Always replace with a new rotor.
2. If not done at removal, now use a C-clamp and clamp both pistons at the same time with a metal plate or wooden block across the face of both pistons. Take care not to damage the pistons or caliper boots.
   NOTE After bottoming the pistons into the caliper bore, lift the inner edge of each caliper boot next to the piston and press out any trapped air. Make sure each boot convolution is tucked back into place. Boots must lay flat.
3. Inspect the caliper bushings for wear. Replace as necessary. Carefully inspect the slide bolts for corrosion. If corrosion if found, use new parts including the bushing assemblies when installing the caliper. Do not attempt to polish away corrosion. Lubricate caliper slide bolts with silicone grease.
4. Install the new inner disc brake pad in the caliper by snapping the shoe retainer springs into the piston making sure both sets of locking tabs are seated in the caliper pistons. The pad must seat flat against the pistons.
5. Install the outer pad into the caliper by snapping the outboard shoe retaining spring over the caliper center lug and into the housing slot. The pad will slide up onto the caliper and the retaining ring will lock into place on the groove in the caliper.
6. The outer pad wear sensor should be at the trailing edge of the shoe during forward wheel rotation.
7. Install the caliper mounting bolts and torque to 80 ft. lbs. (108 Nm).
8. Remove the 2 nuts temporarily securing the rotor.
9. Install the tire and wheel assembly and tighten to specification.
10. Pump the brake pedal several times to seat the pads against the rotor.
11. Check the brake fluid level and top off as necessary.
12. Road test the vehicle to ensure the proper brake performance.

Good job (remember rated and comment this).

If the rear is disc...here ya go!

Removal & Installation

1. Before servicing the vehicle, refer to the Precautions section.
   
2. Remove or disconnect the following:
   
   • 2/3 of the brake fluid from the master cylinder
     
   • Wheels
     
3. Place a C-clamp around the outer pad and caliper; tighten the C-clamp until the piston is fully compressed in the caliper.
   
   • Top caliper retainer, and rotate caliper away from rotor
     
   • Inboard pad and retaining spring from the caliper
     
   • Outboard pad from the caliper
     

To install:

1. Clean and lubricate the sleeves and bushing with silicone lubricant
   
2. Install or connect the following:
   
   • Sleeves and bushings into the caliper
     
   • Clip the retaining spring onto the inboard pad and install the pad in the caliper
     
   • Outboard pad into the caliper
     
   • Caliper in position over the rotor and install the mounting bolts
     
   • Wheel and tire assemblies
     
3. Refill the master cylinder and pump pedal to attain full brake pedal before Road-testing the vehicle.
   

caliper bolts are 7 mm Torx head.

SECTION 206-03: Front Disc Brake 2000 Focus Workshop Manual
REMOVAL AND INSTALLATION Brake Pads Removal
CAUTION: If brake fluid is spilt on the paintwork, the affected area must be immediately washed down with cold water.

1. Loosen the wheel nuts.

1. Raise and support the vehicle. For additional information, refer to Section 100-02 .

1. Remove the wheel.

1. Detach the brake hose from the support bracket.

1. Detach the outer brake pad retaining clip.

1. NOTE: Pull the caliper outwards to release the piston.
   Detach the caliper.
   1. Remove the bolt covers.
   1. Remove the bolts.

1. CAUTION: Suspend the caliper to prevent load being placed on the brake hose.
   Support the brake calipers.

1. Lift the outer pad retaining clip over the spring retaining lugs.

1. Remove the outer brake pad.

1. Remove the inner brake pad.

Installation

1. CAUTION: If the caliper piston is retracted into the housing, brake fluid will be displaced from the master cylinder.
   Fully retract the caliper piston.

1. CAUTION: Make sure the brake disc faces are clean before installation.
   Install the inner brake pad.

1. CAUTION: Make sure the brake disc faces are clean before installation.
   Install the outer brake pad.

1. Push the outer retaining clip over the spring retaining lugs.

1. Install the caliper.
   1. Install the bolts.
   1. Install the bolt covers.

1. Install the brake hose onto the support bracket.

1. Locate the outer pad retaining clip.

1. Install the wheels.

1. Check the fluid level in the brake fluid reservoir.

1.Remove the cap from the brake fluid reservoir

2.Loosen the wheel nuts then raise the vehicle and remove wheel

3.Push the piston back into the bore to provide room for the new brake pads.A C-clamp can be used to accomplish this As the piston is depressed to the bottom of the caliper bore the fluid in the master cylinder will rise.Make sure is doesnt overflow.If necessary drain off some of the fluid. 4.Before removing anything,spray the disc,and brake pads with brake system cleaner dont use compressed air 5.remove the caliper mounting bolt,the banjo fitting for the brake hose shouldnt be disconnected unless you are removing the caliper or hose replacement

6.Swing the caliper up and secure the caliper up towards the spring with a piece of wire then remove the lower and upper anti-rattle springs.Remove the outer brake pad and shim then remove the inner brake pad ans shim(s)

7.Remove and inspect the upper and lower pad retainer clips,the pad retainer clips should fit snugly in the caliper mounting bracket;if they dont,replace them.Apply thin film of high-temperature grease to the retainer

8.Apply anti-squel compound to the back of pads install the new inner pad and shim(s) make sure the "ears" on the upper and lower ends of the pad are fully engaged with their respective grooves and the pad retainer clips

9.Install the new outer pad and shim if new pad has no shim take the old shimoff the old pad and install it on the new outer pad.Install the upper and lower anti-rattle springs

10.Clean off the caliper pin and coat it with high-temperature grease.Lubricate the lower caliper pin with grease too thenswing the caliper down over the disc and new pads (if the piston hits the inner pad depress the piston further into the caliper bore with your c-clamp

11.Install the mounting bolt and tighten it to the torque specifications (44-63) 99 and earlier models (51-55)00 and later models
12.Put the wheel back on and tighten lug nuts

ya gotta be careful if she has antilock or air sensors stuff will break easy an iz EXPENSIVE call auto part store may have instruct. online for ya

If you Need Pics/ Illistrations Email @[email protected]


Brake Pads Replacement - Front

Removal Procedure

Caution: Refer to Brake Dust Caution in Service Precautions.

1. Inspect the brake fluid level in the brake master cylinder reservoir.
2. If the brake fluid is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding.
3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove the brake fluid with appropriate tool to the midway point before proceeding.
4. Raise the vehicle. Refer to Vehicle Lifting.
5. Remove the tire and wheel assembly.

1. Compress the front brake caliper piston.

6.1. Install a large C-clamp over the top of the brake caliper housing and against the back of the outboard brake pad. 6.2. Slowly tighten the C-clamp until the piston pushes into the brake caliper enough to slide the brake caliper off the rotor. 6.3. Remove the C-clamp from the brake caliper.

1. Remove the lower mounting bolt from the slide pin.
2. Rotate the brake caliper upward until it stops.
3. Remove the outboard brake pad.
4. Remove the inboard brake pad.
5. Remove the brake pad retaining clips from the brake caliper mounting bracket.
6. Remove the brake pad retaining clip from the brake caliper.
7. Remove all foreign material from the brake caliper using denatured alcohol.

Installation Procedure

Important: When installing new brake pads, DO NOT reuse the old retaining clips for the brake pad. Use only NEW brake pad retaining clips.

1. Install the brake pad retaining clips to the brake caliper mounting bracket.
2. Install the brake pad retaining clip to the brake caliper.
3. Ensure that the brake pad retaining clip in the brake caliper is properly seated.
4. Install the inboard brake pad.
   
5. Install the outboard brake pad.
6. Rotate the brake caliper down into position.

Notice: Refer to Fastener Notice in Service Precautions.

1. Install the lower brake caliper mounting bolt.

• Tighten the brake caliper mounting bolt to 51 Nm (38 ft. lbs.) .

1. Install the tire and wheel assembly.
2. Lower the vehicle. Refer to Vehicle Lifting.
3. Fill the brake master cylinder reservoir. Caution: Refer to Firm Brake Pedal Caution in Service Precautions.
4. Pump the brake pedal slowly and firmly to seat the brake pads.
5. Burnish the new brake pads.

Installation

1. CAUTION: If the caliper piston is retracted into the housing, brake fluid will be displaced from the master cylinder.
   Fully retract the caliper piston.

1. CAUTION: Make sure the brake disc faces are clean before installation.
   Install the inner brake pad.

1. CAUTION: Make sure the brake disc faces are clean before installation.
   

2. Fully retract the caliper piston

3. Install the outer brake pad.

1. Push the outer retaining clip over the spring retaining lugs.

1. Install the caliper.
   1. Install the bolts.
   1. Install the bolt covers.

1. Install the brake hose onto the support bracket.

1. Locate the outer pad retaining clip.

1. Install the wheels.

1. Check the fluid level in the brake fluid reservoir.

Nothing more special than a basic metric socket set, a good size C-clamp, and maybe a screwdriver. Remove the wheel and unbolt the caliper from the hub (two bolts on the backside, I believe 17mm). Remove the brake fluid reservoir cap. Slide the caliper off the rotor and remove the outer pad. Use the C-clamp against the inner pad to compress the pistons back into the caliper to provide clearance for the new, thicker pads to clear the rotor. Do the same for the outer pistons. Install the new pads, remount the caliper, and put the wheel back on. Replace the fluid cap, pump up the brake pedal for pressure, then take it out and bed the pads in with several back to back stops from 30mph with steady, even pressure on the pedal. You'll be good to go at that point.