2004 Ford Explorer Brake Service (ONLINE REPAIR MANUALS)

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We have info for following modifications of 2004 Ford Explorer

  • 2004 Ford Explorer 4.6 V8 GAS, CID:281, Fuel Injection, Aspiration:281, Engine VIN:, Desg:W
  • 2004 Ford Explorer 4.0 V6 GAS, CID:245, Fuel Injection, Aspiration:245, Engine VIN:, Desg:E
  • 2004 Ford Explorer 4.0 V6 FLEX, CID:245, Fuel Injection, Aspiration:245, Engine VIN:, Desg:K

BRAKE SERVICE PROCEDURES FOR 2004 Ford Explorer AUTOMOBILES

Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2004 Ford Explorer cars and light trucks from 1990+.

Power Brake Units -> Bendix Vacuum Brake Booster -> Adjustments -> E-Series, Expedition, Explorer, Explorer Sport & Sport/Trac, F-150, F-Super Duty, Mark LT, Mountaineer & Navigator -> Pushrod -> Ranger
Vehicle: 2004 Ford Explorer 4.0 V6 GAS

Pushrod

E-Series, Expedition, Explorer, Explorer Sport & Sport/Trac, F-150, F-Super Duty, Mark LT, Mountaineer & Navigator
  • On Expedition, F-150, Mark LT and Navigator models, adjust brake booster to master cylinder pushrod length to .980-.995 inch, Fig. .
  • On Explorer, Explorer Sport and Sport/Trac and Mountaineer models, adjust brake ...

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BRAKE SERVICE PROCEDURES FOR 2004 Ford Explorer AUTOMOBILES

Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2004 Ford Explorer cars and light trucks from 1990+.

Power Brake Units -> Bendix Vacuum Brake Booster -> Description
Vehicle: 2004 Ford Explorer 4.0 V6 FLEX

The single and tandem vacuum boosters, Figs. and , are self contained vacuum hydraulic power braking units. These are vacuum suspended units that use vacuum and atmospheric pressure for their power.

On models equipped with gasoline engines, vacuum is supplied through a fitting in the intake manifold. On models equipped with diesel engines, vacuum is supplied through a vacuum pump.

The three basic elements of the booster are the vacuum power chamber, mechanically actua...

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BRAKE SERVICE PROCEDURES FOR 2004 Ford Explorer AUTOMOBILES

Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2004 Ford Explorer cars and light trucks from 1990+.

Drum Brakes -> Expedition, Explorer, E-Series, F-Series, Mountaineer, Navigator & Ranger -> Inspection -> Adjuster Mechanism -> Backing Plate -> Brake Drums -> Brake Linings & Springs -> Parking Brake Cable
Vehicle: 2004 Ford Explorer 4.0 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 2004 Ford Explorer AUTOMOBILES

Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2004 Ford Explorer cars and light trucks from 1990+.

Hydraulic Brake Systems -> Brake System Bleed -> Anti-Lock Brake System Hydraulic Control Unit -> Anti-Lock Brakes -> Aviator, Explorer & Mountaineer -> Bench -> Caliper -> E-Series, F-150 & Mark LT -> Escape & Mariner -> Excursion, Explorer Sport/Sport Trac, Freestar, F-Super Duty, Monterey, Motorhome & Ranger -> Expedition & Navigator -> Four Wheel Anti-Lock Brake System -> Gravity Bleed -> In Vehicle -> Manual -> Manual Bleed -> Master Cylinder -> Pressure -> Pressure Bleed
Vehicle: 2004 Ford Explorer 4.6 V8 GAS

Aviator, Explorer & Mountaineer

Master Cylinder
  • Connect one end of a clear flexible hose to master cylinder bleeder screw. Submerge other end in a container partially filled with suitable brake fluid.
  • Have an assistant pump and then hold firm pressure on brake pedal.
  • Open master cylinder bleeder screw until brake fluid flows into container.
  • When fluid stops flowing, close bleeder screw.
  • Repeat procedure until there are no air bubbles in fluid.
  • Have an assistant pump and then hold firm pressure on brake pedal.
  • Loosen a master cylinder tube fitting at anti-lock brake hydraulic control ...

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BRAKE SERVICE PROCEDURES FOR 2004 Ford Explorer AUTOMOBILES

Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2004 Ford Explorer cars and light trucks from 1990+.

Hydraulic Brake Systems -> Component Replacement -> Aviator -> E-Series -> Escape & Mariner -> Excursion & F-Super Duty -> Expedition, Explorer, Explorer Sport & Sport/Trac, F-150, Mark LT, Mountaineer & Navigator -> Freestar & Monterey -> Less Hydro Max -> Master Cylinder -> Ranger -> With Hydro-Max
Vehicle: 2004 Ford Explorer 4.6 V8 GAS

Master Cylinder

Aviator

Remove components in sequence illustrated, Fig. .

E-Series
  • Drain brake master cylinder with suitable suction device.
  • Remove coolant reservoir.
  • On models equipped with Hydro Boost, remove three power distribution box bracket bolts and position box aside.
  • On all models, remove speed control deactivator switch.
  • Disconnect fluid level sensor connector.
  • Remove and discard master cylinder mounting nuts.
  • Disconnect master cylinder brake tubes.
  • Remove master cylinder cylinder.
  • Reverse procedure to install, noting the following:
    • Torque master cylinder mounting nuts to 18...

CLICK HERE TO GET FULL ACCESS TO 2004 Ford Explorer BRAKE SERVICE PROCEDURES

BRAKE SERVICE PROCEDURES FOR 2004 Ford Explorer AUTOMOBILES

Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2004 Ford Explorer cars and light trucks from 1990+.

Disc Brakes -> Inspection -> Brake Bleed -> Brake Disc Service -> Brake Linings -> Brake Roughness -> Caliper Inspection -> General Precautions
Vehicle: 2004 Ford Explorer 4.0 V6 FLEX

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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