Disc Brakes: Helpfull hint.

Front Brake Caliper: All But FLSTS/FXSTS

Remove the front master cylinder reservoir cap to be able to check the fluid level as the caliper pistons are pushed back into the caliper because the fluid level may rise more than the 1/8 in. (3.2 mm) from the top level and you may have to remove some excess fluid if it does so. THEN loosen but do not remove both pad pins with a 12 point one quarter inch socket. THEN remove both metric caliper mounting bolts and remove the caliper from the front forks and brake disc and pry the pads back to force all four caliper pistons into their bores. THEN once the pistons have been retracted, remove the pad pins and the brake pads.

Although the front and rear brake calipers except FXSTD models, use the same exact brake pad set the FXSTD does not and the FXSTD rear pads have a vertical slot cut into the pads. Be sure NOT to substitute front and/or rear brake pads for the other on these bikes. On the right side of the vehicle the pad with the two tabs installs on the inboard side of the caliper and on the left side of the vehicle, the pad with the two tabs installs on the outboard side of the caliper.

THEN install new pads into the caliper noting that the curved portion of the pad faces to the rear of the bike, and loosely install the pad pins until you hear an audible click from them. THEN re-attach the caliper to front fork, place the caliper over the brake disc with the bleeder valve facing upwards, loosely install the long caliper mounting bolt into the top hole on the fork leg, install the short mounting bolt into the bottom hole on the fork le, tighten the bottom mounting bolt to 28-38 ft-lbs (38.51.5 Nm) and final tighten the top mounting bolt also to 28-38 ft-lbs (38.51.5 Nm) and final tighten the two pad pins to 180-200 in-lbs (20.3-22.6 Nm).

THEN and whenever new pads are installed, before moving the bike pump the brakes until brake fluid pushes the caliper pistons and the pads out and verify that the pads are against the brake disc and then rotate the wheel to ensure there is not any excessive drag between the pads and the disc, check for proper fluid level in the reservoir and if necessary top it up with DOT 5 Silicone base brake fluid only, install the reservoir cover and tighten its screws to 6-8 in-lbs (0.7-0.9 Nm).

THEN and whenever any work has been done on brakes always test the brakes at low speed before operating on a roadway or at higher speeds. THEN test brake system light and if during the road test the brakes feel spongy at all bleed the system and after obtaining a hard lever or pedal road test the bike again.

CAUTION: Always replace all brake shoes and linings on an axle. Never replace only one wheel (1007).

1. To avoid fluid overflow when the caliper pistons are pressed into the caliper cylinder bores, siphon or dip part of the brake fluid out of the brake master cylinder reservoir (2K478). Discard the removed fluid.
   

1. Raise the vehicle and install safety stands. Remove the front wheel and tire assembly.
   

1. Place an appropriate size C-clamp on the disc brake caliper with end of clamp against caliper and end of screw against outer shoe. Tighten the clamp to bottom the caliper pistons in the cylinder bores. Remove the clamp. Do not use a screwdriver or similar tool to pry caliper pistons (2196) away from the front disc brake rotor (1125).
   
   
   
   
   

1. Clean excess dirt from area around pin tabs.
   

1. Tap upper caliper pin toward inboard side until pin tabs touch the front wheel spindle.
   

1. Using Hydraulic Caliper Pin Remover D89T-2196-A or equivalent and a light hammer, drive the pin from the disc brake caliper as follows:
   
   1. Position the notched end of the tool against the caliper pin (retention tab half), at a 45-degree angle from the pin retention tabs.
      
      
      
      
   1. Tap the tool with the hammer to compress the retention tabs.
      
      
      
      
   1. As the retention tabs are compressed, move the tool to gain a straight approach to the caliper pin, and continue tapping to drive the caliper pin through the caliper/spindle groove.

1. Repeat removal procedure for lower caliper pin.
   

1. CAUTION: Do not let the disc brake caliper hang by the front brake hose (2078). The front brake hose could become stretched or twisted which can cause the front brake hose to leak and rupture, resulting in failure.
   Remove the disc brake caliper from the front disc brake rotor. If the disc brake caliper is to be removed for service, remove the front brake hose from the disc brake caliper. Plug the end of the front brake hose to prevent fluid loss and entry of air into the system. If the disc brake caliper is not to be removed, wire it up to the frame of the vehicle to avoid damage to the front brake hose.
   

CAUTION: Always replace all brake shoes and linings on an axle. Never replace only one wheel.

1. NOTE: There is a raised section at one end of each shoe so installation can be made in one direction only.
   
   Install new inner and outer lining.
   

1. Lubricate the knuckle upper and lower inner pad grooves and caliper grooves with Disc Brake Caliper Slide Grease, Silicone Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A. Install the disc brake caliper on a front wheel spindle, making sure the mounting surfaces are free of dirt.
   

1. CAUTION: Do not allow the tabs of the caliper pin to be tapped too far into the spindle groove. If this happens it will be necessary to tap the other end of the caliper pin until the tabs snap into place. The tabs on each end of the caliper pin must be free to catch on the spindle flanks.
   Position caliper pin with the pin retention tabs oriented adjacent to the spindle groove.
   

1. Tap the caliper pin on the outboard end with a hammer. Continue tapping the caliper pin inward until the retention tabs on the sides of the caliper pin contact the spindle face. Repeat procedure for the lower caliper pin.
   
   
   

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.

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.

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.

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.

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.

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.

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.

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

1. Raise vehicle on hoist.
   

1. Remove wheel and tire assembly. Refer to Section 04-04 .
   

1. Remove disc brake caliper (2B120), and front disc brake rotor (1125). Refer to Section 06-03 .
   

1. Remove brake master cylinder filler cap (2162). Check fluid level in brake master cylinder reservoir (2K478). Remove brake fluid until brake master cylinder reservoir is half full. Discard removed fluid.
   

1. Raise vehicle on hoist. Refer to Section 00-02 .
   

1. Remove wheel and tire assembly from front disc brake rotor mounting face. Use care to avoid damage or interference with disc brake caliper (2B120), front disc brake rotor shield (2K004) or front wheel knuckle (3K185).
   

1. Remove rear brake pin retainers (2N386). ( I think it is a T 40 torx bit you need)
   

1. NOTE: It is not necessary to disconnect hydraulic connections.
   
   Lift disc brake caliper from front disc brake caliper anchor plate (2B292) and front disc brake rotor (1125). Do not pry directly against metal caliper piston or damage will occur.
   

1. Position disc brake caliper out of the way and support with wire to avoid damaging the disc brake caliper and front brake hose (2078).
   

1. Remove outer brake shoe and lining (2001) assembly from front disc brake caliper anchor plate.
   

1. Remove inner brake shoe and lining assembly.
   

1. Position lug bolt (1107) to clear front wheel knuckle (3K185).
   

1. Remove lug bolt from wheel hub (1104).
   
   
   
   

1. Install lug bolt into wheel hub.
   

1. Using a lug nut (1012), seat wheel hub bolt into wheel hub.
   

1. Install front disc brake rotor and disc brake caliper. Refer to Section 06-03 .
   

1. Install wheel and tire assembly. Tighten lug nut to 115-142Nm (85-104 lb-ft).
   

1. Disconnect the brake hose.
2. Remove bolt.
3. Disconnect the rear wheel brake hose (2A442).
4. Remove the copper washers and plug the brake hose.
Disconnect the brake hose.
1. Remove bolt.
1. Disconnect the rear wheel brake hose (2A442).
1. Remove the copper washers and plug the brake hose.
1. CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The guide pins are meant to be sealed for life and are not repairable. Use Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A for re-lubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in contamination and accelerated corrosion or wear of the caliper slide pin mechanism.
   Remove the rear disc brake caliper (2552).
   1. Remove the brake caliper bolts (2W303).
   1. Lift the rear disc brake caliper off the rear disc brake caliper anchor plate (2C220).
1. Inspect the rear disc brake caliper for leaks.
   • If leaks are found, disassembly is required. Refer to Caliper in this section.
Installation

1. CAUTION: To prevent interference with rear disc brake caliper operation, install only the correct caliper bolt.
   NOTE: Make sure the stainless steel shoe slippers are correctly positioned. Install new slippers if worn or damaged.
   NOTE: When installed, the locator notch on the brake pads will be located at the upper end of the rear disc brake caliper.
   Install the rear disc brake caliper.
1. Install the rear wheel brake hose.
   • Connect the brake hose and install the caliper flow bolt.
     • Use new copper washers.
1. Bleed the disc brake caliper. For additional information, refer to Section 206-00 .
1. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch.
   Install the wheel and tire assembly. For additional information, refer to Section 204-04 .
1. Verify correct brake operation.
5. CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The guide pins are meant to be sealed for life and are not repairable. Use Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A for re-lubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in contamination and accelerated corrosion or wear of the caliper slide pin mechanism.
   Remove the rear disc brake caliper (2552).
   1. Remove the brake caliper bolts (2W303).
   1. Lift the rear disc brake caliper off the rear disc brake caliper anchor plate (2C220).

1. Inspect the rear disc brake caliper for leaks.
• If leaks are found, disassembly is required. Refer to Caliper in this section.

1. NOTE: When removing the rear brake disc (2C026) in this procedure it is not necessary to disconnect the hydraulic lines.
   Remove the rear disc brake caliper (2552). For additional information, refer to Caliper in this section.

1. NOTE: If the rear brake disc binds on the rear parking brake shoe and linings, remove the adjustment hole access plug and contract the parking brake shoe and lining.
   Remove the rear brake disc.

1. CAUTION: Use a hub-mount brake lathe if necessary to machine the rear brake disc.
   Measure the rear brake disc, and resurface as necessary. Install a new rear brake disc if beyond specification.

1. CAUTION: To prevent interference with rear disc brake caliper operation, install only the correct caliper bolt.
   NOTE: Make sure the stainless steel shoe slippers are correctly positioned. Install new slippers if worn or damaged.
   NOTE: When installed, the locator notch on the brake pads will be located at the upper end of the rear disc brake caliper.
   Install the rear disc brake caliper.

1. Install the rear wheel brake hose.
   • Connect the brake hose and install the caliper flow bolt.
     • Use new copper washers.

1. Bleed the disc brake caliper. For additional information, refer to Section 206-00 .

1. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension switch.
   Install the wheel and tire assembly. For additional information, refer to Section 204-04 .

1. Verify correct brake operation.