Hi guys, sorry for the non-thirdgen question, but I'm about to do some work for a friend. He's got a 1992 Mazda Navaho, which is supposed to be the exact same as a '92 Ford Explorer. His brakes are shot, and the local shop quoted him a huge price, so he asked me for help. I can't get to the truck easily (it's in another state), and we'll be doing the job after he gets off work, so no parts stores will be open that late.

I was wondering if anyone knew the size of the allen key needed to do the front calipers? Or, does Ford not use the allen wrench, but the torx sockets?

Thanks in advance!

 

I'd say be prepared. Take torx and allens. Take a big assortment of each so you won't get half way through the job and can't continue.

 

Wow; so nobody knows, eh?

 

Tom, I've got a '94 Explorer, 4x4, IIRC it's a metric size...something kinda large...8, 10mm...the wife has it out now, if she gets back at a decent time, I'll check it out.

There's also a few differences that you may not be aware of (if his is like mine) there's a caliper pin, that is split, with a rubber inside of it, you need a smallish diameter (about 1/4in) drift punch about 6-8 inches long to drive it out. Ford recommends replacement of this pin, and the use of new caliper grease on it, when you pull the calipers..I've been lucky and have been able to reuse mine through the last two pad changes.

Also, note the orientation of the front hub and spring mechism when you pull it off...it's easy to install it and not get it seated properly..when you put the hub back on, you'll notice that once it seats, it will want to "spring out" at you, so keep pressure on it as you put the wheel back on, so it stays in place. All this assumes it is like mine...I know that '91-'94 Explorers are pretty much the same. Also, Ford recommends cleaning and greasing the 4x4 hub assy at the same time.

 

Yep, it was a caliper Pin, not a caliper bolt. I ate $15 for a Haynes book on the Explorer; that's alright, I'm starting a little "mini library" of every car I work on. Seems like front caliper bolts started in the '95 model year.

I found out about the pins at 8:40 at night; luckily, I made it to a parts store in time to take their last two sets from them. Good thing I bought them (and caliper grease), too. One pin split as we removed it. On the passenger side, the pin was sticking almost all the way out!! The piece left inside the caliper was a little under an inch long- scary stuff. Makes me glad I have caliper bolts and not pins!

The front calipers were cake; I didn't think to check about greasing those hubs, thanks for the info. Next time I'm up there, we'll have to take care of that. Is there a procedure for cleaning/degreasing that area? Or do we just stuff some new grease (what kind, synthetic chassis lube ok?) in there?

The rear drums, man, what a problem. One drum was rusted to the hub, but I managed to get it off by using all the methods the guys here gave me on how to get -my- rusted drum off. (The thing still won't come off, by the way.) The other side wasn't rusted to the hub, but the shoes were locking it on.

It also turned out that the shop was completely wrong about him needing new brakes all around. The fronts were FINE. He had enough pad on there to last him another year. It was only the rears that were pretty thin, and still, they could've lasted a while, too.