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October 16, 2026, 10:54:10 AM

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[CortinaD]

It was originally submitted to FAF by Bucster.

Click to see the original thread.

http://www.fordaustraliaforums.com/forum/showthread.php?t=16121


Hey all.
Thought this might be useful for anyone wanting to change their Disc rotors, brake pads, wheel bearings, seals etc.

Step #1.

Place the vehicle up on a suitable rest, jack stands etc. Do not recommend working of the jack as this is a dangerous habit waiting for an accident to happen.


Step #2.

Remove the wheel, undo the 2 bolts holding the brake caliper and remove caliper from disc rotor, take out the 4 bolts immediately visible on the hub and remove the bearing dust cap for access to the capsulated nut. Remove the split pin, then the capsulated nut and the main nut securing the assembly to the stub axle.


Step #3.

Using a large screwdriver or wedge separate the brake hub from the disc rotor.



Step #4.

Remove the old bearings, they come off in the hand and visually inspect the stub axle and hub for damage, scores, heat marks, etc.



Step #5.

Practice fit the new bearing in the old race ONLY if the initial inspection showed no problems with the inner race.
This inner race was still in good condition so there was no need to replace it.



Step #6.

Pack the bearing with a suitable high temperature wheel bearing grease.
This is done by forcing the grease through the bearing from the side with the slot around the bearing face. Place the grease in the palm of your hand and drag the bearing through it.



When done correctly grease will be visible protruding through the bearing rollers all the way around the bearing


Step #7.

Sit the bearing back into the race, apply some grease around the bearing lip ready for the bearing seal.


Gently tap the seal into the hub until its home.


Now turn the hub over to access the other side.


Step #8.

Pack the small bearing with grease exactly the same way as the larger bearing. Place into the bearing race.



Step #9.

While your hands are still all greasy, put some onto the stub axle.


Step #10.
Reassemble the hub and new disc rotor.



Always use new bolts and washers supplied with most kits.


Loctite is the safest way to keep them in place, we used Loctite 262 threadlocker.


Ensure the hub and disc rotor seated correctly with no gaps on the mating surfaces.


Step #11.

Lift the complete assembly, being carefully not to drop the bearing out, ready to replace back onto the stub axle.



Step #12.

Replace the washer and the nut and tighten firmly to seat the bearings.



Step #13.

Loosen the nut back off 1 turn, spin the disc a couple of times and retighten the nut using light pressure only.


Step #14.

Replace the capsulated nut and the split pin securing the assembly.



Apply grease into the bearing cap, towards the bottom, it doesnt need to be full.


Step #15.

Wipe the disc rotor clean to get rid of the surface protectant, we used some petrol on a rag to accomplish this task.

Change the brake pads. Easiest way is to use this nifty tool to squeeze the piston back into the caliper. Notice we used the old pad to rest the tool and apply even pressure. All pads are the same, so u cant mix them up. Place the new pads in the brake caliper ensuring they seat correctly in the locater lugs.





If you used the nifty brake tool there should be enough gap to replace the caliper directly onto the rotor.


Step #16.

Relace the caliper, insert and tighten the 2 bolts holding the caliper. Use some mig wire pushed through the holes in the 2 bolts to tie the assembly securely.



Step #17.
Tighten the 4 bolts on the hub securely NOW....


One side completed, do exactly the same for the opposite side.



Hope this Howto helped somebody. its an easy job to complete and can be done by most competent persons.


Cheers
Bucster