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Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 2002 Ford Windstar car and truck
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BRAKE SERVICE PROCEDURES FOR 2002 Ford Windstar AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2002 Ford Windstar cars and light trucks from 1990+.
Disc Brakes -> Caliper Service -> Assemble -> Aviator -> Cleaning & Inspection -> Disassemble -> E & F Series -> E-150, E-250, E-350 & E-450 -> E-250, E-350 & E-550 -> E-450 -> E-550 -> E-Series -> Escape -> Excursion, Expedition, F-Super Duty, Motorhome & Navigator -> Excursion, F-Super Duty & Motorhome -> Expedition & Navigator -> Explorer & Mountaineer -> Explorer Sport/Sport Trac -> Explorer, Explorer Sport/Sport Trac, Mountaineer & Ranger -> F-Series -> Front -> Inspection -> Installation -> Overhaul -> Ranger -> Rear -> Removal -> Replacement -> Villager -> Villager & Windstar -> Windstar
Vehicle: 2002 Ford Windstar 3.8 V6 GAS
Replacement
Aviator
Front
- Raise and support vehicle.
- Remove front tire and wheel assemblies.
- Remove components in sequence, Fig. .
- Reverse procedure to install.
Rear
Refer to Fig. , and remove rear brake components in sequence listed.
E-Series
Front
E-150, E-250, E-350 & E-450
- Raise and support vehicle, remove front tire and wheel assemblies.
- Unclip speed sensor wiring from front brake hose.
- Disconnect and plug front brake caliper hose from caliper. Discard copper sealing rings.
- Remove two disc caliper mounting bolts, then the caliper, Fig. .
- Reverse procedure to install, noting the following:
- F...
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BRAKE SERVICE PROCEDURES FOR 2002 Ford Windstar AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2002 Ford Windstar cars and light trucks from 1990+.
Drum Brakes -> Escape, Villager & Windstar -> Inspection -> Adjuster Mechanism -> Backing Plate -> Brake Drums -> Brake Linings & Springs -> Parking Brake Cable
Vehicle: 2002 Ford Windstar 3.8 V6 GAS
Brake Drums
Any time brake drums are removed for brake service, braking surface diameter should be inspected with a suitable micrometer at several points to determine if they are within the safe oversize limit stamped on the brake drum outer surface. If braking surface diameter exceeds specifications, the drum must be replaced. If braking surface diameter is within specifications, drums should be cleaned and inspected for cracks, scores, deep grooves, taper, out of round and heat spotting. If drums are cracked or heat spotted, they must be replaced.
Minor scores should be removed with ...
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BRAKE SERVICE PROCEDURES FOR 2002 Ford Windstar AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2002 Ford Windstar cars and light trucks from 1990+.
Disc Brakes -> Inspection -> Brake Bleed -> Brake Disc Service -> Brake Linings -> Brake Roughness -> Caliper Inspection -> General Precautions
Vehicle: 2002 Ford Windstar 3.8 V6 GAS
Brake Linings
Remove both front wheels and inspect the brake discs, calipers and linings. (Wheel bearings should be inspected at this time and repacked if required).
Do not get any oil or grease on the linings. It is recommended that both front wheel sets be replaced whenever a respective shoe and lining is worn or damaged. Inspect and, if required, replace rear brake linings also.
If the caliper is cracked or fluid leakage through the casting is evident, it must be replaced as a unit.
Brake Roughness
The most common cause of brake chatter on disc brakes is a variation in thickness of the...
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BRAKE SERVICE PROCEDURES FOR 2002 Ford Windstar AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2002 Ford Windstar cars and light trucks from 1990+.
Disc Brakes -> Rotor Replacement -> 1999-2001 -> 2002-03 -> Aviator -> E-Series -> Escape -> Excursion, F-Super Duty & Motorhome -> Expedition & Navigator -> Explorer & Mountaineer -> Explorer Sport/Sport Trac -> F-250 & F-350 2WD -> F-250 & F-350 4WD, F-450 & F-550 -> F-Series -> Front -> Installation -> Motorhome -> Ranger -> Rear -> Removal -> Windstar & Villager
Vehicle: 2002 Ford Windstar 3.8 V6 GAS
Aviator
Front
- Raise and support vehicle.
- Remove front tire and wheel assemblies.
- Remove front brake components in sequence, Fig. .
- Reverse procedure to install.
Rear
Refer to Fig. , and remove rear brake components in sequence listed.
Escape
- Remove disc brake caliper and anchor plate as outlined in "Caliper Service".
- Remove rotor
- Reverse Procedure to install. Tighten all nuts and bolts to specification.
E-Series
Front
Refer to Figs. through , and remove components in sequence listed.
Rear
Removal
- Remove disc brake caliper, refer to "Caliper Service."
- Remove axle shafts as outlined in "Rear Axle & S... "
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BRAKE SERVICE PROCEDURES FOR 2002 Ford Windstar AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2002 Ford Windstar cars and light trucks from 1990+.
Hydraulic Brake Systems -> Description -> Bendix Hydro-Boost Brake Booster -> Bendix Hydro-Max Brake Booster -> Combination Valve -> Height Sensing Proportioning Valve -> Hydraulic Control Unit (HCU) -> Hydraulic Control Valves -> Integral Bypass Proportioning Valve -> Master Cylinder
Vehicle: 2002 Ford Windstar 3.8 V6 GAS
Master Cylinder
The master cylinder consists primarily of a hydraulic cylinder, primary and secondary hydraulic pistons and a single or dual chamber fluid reservoir. The front brakes are connected to the primary outlet port(s) and are actuated by the primary piston assembly. The rear brakes are connected to the secondary outlet port and are actuated by the secondary piston assembly.
Hydraulic Control Valves
Combination Valve
This multi-function hydraulic control unit consists primarily of a pressure differential valve, brake lamp warning switch and a proportioning valve. A pressure diff...
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BRAKE SERVICE PROCEDURES FOR 2002 Ford Windstar AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2002 Ford Windstar cars and light trucks from 1990+.
Anti-Lock Brakes -> Windstar -> System Service -> ABS Control Module -> Brake Sensors -> Brake System Bleed -> Component Replacement -> Front -> Hydraulic Control Unit (HCU) -> Manual -> Pressure -> Rear
Vehicle: 2002 Ford Windstar 3.8 V6 GAS
Brake System Bleed
Manual
Bleed sequence is righthand rear, lefthand rear, righthand front and lefthand front.
- Clean all dirt from master cylinder filler cap, then remove cap.
- Fill brake master cylinder reservoir.
- Attach a rubber drain tube to righthand rear bleeder screw and submerge opposite end in container partially filled with clean brake fluid.
- With aid of an assistant, pump and hold pressure on brake pedal.
- Loosen righthand rear bleeder screw until stream of fluid comes out, then tighten bleeder screw.
- Repeat steps four and five until clear, bubble free fluid comes out.
- Fill brake ...
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