Caliper Removal on a '96 Aerostar

In the 1986 model year, Ford decided to take a shot at the minivan market with the release of the Aerostar. The Aerostar was unlike other minivans of its era, as Ford based it on the same platform as the Ranger, making it a rear-wheel drive vehicle that handled more like a pickup than a car. By 1996, the Aerostars production life was coming to an end, as Ford was set to eliminate it after the 1997 model year. The standard brake configuration on the 1996 Aerostar was front disc and rear drum, and replacing the calipers on the standard front brakes is slightly unusual, as two compression pins secure the caliper instead of bolts.

Instructions

Loosen the front lug nuts with a ratchet and socket, and raise the front of the Aerostar with a floor jack. Slide jack stands under the vans frame rails and lower the vehicle onto the jack stands. Remove the lug nuts and pull the wheels from the vehicle.

Wrap a thick shop cloth around the middle of the brake caliper hose and clamp a set of locking pliers over the shop cloth to seal the hose shut. Position a drain pan under the caliper hose and remove the banjo bolt securing the hose to the caliper, using a ratchet and socket. Remove the banjo bolt, then pull the hose and two brass washers from the caliper.

Position a caliper pin removal tool, Ford tool No. D89T-2196-A, or an equivalent drift punch on the upper caliper pin, so it is at approximately a 45-degree angle to the retaining tabs on the pin. Strike the caliper pin removal tool or drift punch with a hammer to compress the caliper pin until it starts sliding into its hole between the caliper and bracket. Adjust the caliper pin removal tool or drift punch so it is in a direct line with the caliper pin and lightly strike the tool with a hammer until the caliper pin falls from the rear of the caliper. Repeat this step on the lower caliper pin and remove the caliper.

Press both ends of the outer brake pad toward the inner brake pad to disengage the tabs on the pad from the grooves in the caliper, then remove the brake pad. Pull the inner brake pad toward the outer part of the caliper to remove the pad and its metal retaining fingers from the cavity in the caliper piston.

Repeat steps 2 through 4 to remove the caliper on the other side of the Aerostar, if needed.

Align the metal retaining fingers on the rear of the inner brake pad with the cavity in the new calipers piston. Press the pad toward the piston until it seats on top of the piston. Press the outer brake pad onto the outer part of the caliper until its two tabs seat into their cutouts in the calipers body.

Position the caliper into its bracket.

Apply a generous coat of disc brake grease meeting Ford specification ESA-M1C172-A onto the new caliper pin, which comes with a new caliper. Insert the new caliper pin into the hole between the caliper and its bracket, so the tabs on the end of the pin are on the outer end of the caliper pin, and lightly strike the end of the caliper pin until the outer tabs on the pin seat against the caliper bracket. Repeat this step on the lower caliper pin to lock the caliper into place.

Slide a new brass washer two new washers come with the new caliper onto the caliper hoses banjo bolt and insert the banjo bolt through the hole in the end of the brake line. Slide the second washer onto the banjo bolt and hand-thread the bolt into the caliper. Tighten the banjo bolt to between 30 and 39 foot-pounds with a torque wrench and socket.

Release the locking pliers from the brake caliper hose and unwrap the shop towel from the hose.

Repeat steps 1 through 5 to reinstall the other caliper, if applicable.

Bleed the brakes.

Unscrew the cap from the master cylinder reservoir and add DOT 3 brake fluid to the reservoir until the fluid level reaches the Max line.

Find the bleeder valve the 1/4-inch metal valve on the right-front brake line and press a 1/4-inch-diameter rubber hose on the valve. Set the other end of the hose into a clean, clear container.

Fill the clean and clear container with new DOT 3 brake fluid until the fluid submerges the end of the rubber hose.

Open the bleeder valve by turning it 3/4 of a turn counterclockwise with a combination wrench and instruct an assistant to slowly press the brake pedal to the floor. Watch the submerged end of the brake hose for air bubbles.

Close the bleeder valve and instruct your assistant to release the brake pedal.

Repeat steps 3 and 4 until no air bubbles come from the end of the rubber hose.

Remove the rubber hose from the bleeder valve and fill the master cylinder reservoir to the Max line with new DOT 3 brake fluid.

Repeat steps 4 through 7 to bleed the left-front caliper, if you replaced it.

Reinstall the front wheels on the front hubs and hand-tighten the lug nuts. Raise the van off the jack stands with a floor jack and remove the jack stands. Lower the van to the ground and torque the lug nuts, in a crisscross pattern, to 100 foot-pounds with a torque wrench and socket.