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Someone had already snagged the caliper brackets, so a lot of the work was already done, including loosening the wheelwells. I found the brackets on a nearby car without much effort.
Disc Removal
1. Raise vehicle on hoist.
CAUTION: Use care to avoid damage to the front disc brake rotor (1125) and nicking, scratching, or contamination of the brake shoe and lining (2001) .
2. Remove the wheel and tire assembly from the wheel hub (1104) . Be careful to avoid damage to or interference with the bleeder screw and front disc brake rotor shield (2K004) .
3. Remove two caliper anchor plate bolts and discard.
4. Remove the front disc brake caliper (2B120) & anchor plate (2B292) assembly from the front wheel spindle (3105) and rotor .
5. If the front disc brake caliper does not require servicing, it is not necessary to disconnect the front brake hose (2078 ). Position the front disc brake caliper out of the way, and support it with a wire to avoid damaging the disc brake caliper or stretching the front brake hose .
6. Mark the front disc brake rotor and lug bolt position to aid assembly.
7. Punch out the mandrels from the rotor-to-hub rivets.
8. Using a 9.5-mm (3/8-in.) drill, remove the heads from the rotor-to-hub rivets.
CAUTION: Use care to avoid rotor damage while drilling.
9. Remove the front disc brake rotor from the wheel hub.
CAUTION: If excessive force is used to remove the front disc brake rotor , the rotor total indicated runout (TIR) must be checked. Refer to Section 06-00 .
NOTE: If the front disc brake rotor does not come off easily, apply Rust Penetrant and Inhibitor F2AZ-19A501-A or equivalent meeting Ford specification ESR-M99C56-A, then strike the front disc brake rotor between the lug bolts with a soft-faced hammer.
10. If necessary, remove any remaining chips or rivet sleeves.
Installation
NOTE: Rotor machining is not necessary for minor scoring or lining material buildup.
1. Clean the hub mounting surface of the front disc brake rotor as well as the hub mounting surface for rust, scale or dirt. The contamination will not allow front disc brake rotor to sit flat to the hub surface.
If the front disc brake rotor is being replaced, remove the protective coating from the new front disc brake rotor with Metal Brake Parts Cleaner (Non-Chlorinated) F5AZ-2C410-AA or equivalent.
Lubricate the hub mounting surface with High Temperature Nickle Anti-Seize Lubricant F6AZ-9L494-AA or equivalent meeting Ford specification ESE-M12A4-A prior to installing the front disc brake rotor .
2. Align the painted match marks and position the front disc brake rotor assembly on the wheel hub .
3. Rivet the front disc brake rotor to the wheel hub .
4. Install disc brake caliper / front disc brake caliper anchor plate assembly onto front disc brake rotor .
5. Install two new caliper anchor plate mounting bolts and tighten to 170-230 Nm (125-169 lb-ft).
6. Install wheel and tire assembly, using Rotunda Accutorq® Lug Nut Sockets 164-R0303 or equivalent on 1/2 inch drive air impact wrench or torque wrench to tighten lug nuts to 115-142 Nm (85-104 lb-ft).
CAUTION: Failure to tighten lug nuts (1012) in a star pattern can result in high rotor runout, which will speed up the development of brake roughness, shudder and vibration.
Check rotor total indicated runout (TIR). Refer to Section 06-00 .
7. Lower vehicle.
8. Pump brake pedal (2455) several times to position brake shoes and linings .
9. Road test vehicle.
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