Torque specs

front

1. Install or connect the following:
   • Strut assembly
   • Fork to the strut and torque the bolts to 59 ft. lbs. (80 Nm)
   • Fork to the lower arm and torque the bolt to 88 ft. lbs. (120 Nm)
   • Upper strut mounting nuts and torque to 36 ft. lbs. (50 Nm)
   • Brake hose bracket
   • Front wheel
2. Check and/or adjust the wheel alignment.

--------------------rear------------

To install:

1. Install or connect the following:
   • Strut assembly and mounting bracket and torque the bolt to 36 ft. lbs. (50 Nm)
   • Upper arm and rear carrier bolt and torque the bolt to 88 ft. lbs. (120 Nm)
   • Lower mounting bolt
   • Rear wheel

Cylinder head Renew bolts: Yes Tighten: 25 Nm Tighten: 90° Tighten: 90° Tighten: 90° Other engine tightening torques Main bearings Renew bolts/nuts: Yes Main bearings Stage 1: 50 Nm Main bearings Stage 2: 45°-60° Big end bearings Renew bolts/nuts: Yes Big end bearings Stage 1: 35 Nm Big end bearings Stage 2: 45°-60° Oil pump to cylinder block : 6 Nm Sump bolts : 15 Nm Sump drain bolt : 55 Nm Flywheel/driveplate :

• Use new bolts and tighten as follows:
  • 1,4/1,6 = 35 Nm + 30° + 15°
  • 1,8/2,0 = 65 Nm + 30° + 15°
• "Pot"-type flywheel = 65 Nm + 30° + 15°
• Tighten drive plate to 60 Nm.

Clutch pressure plate : 15 Nm Crankshaft pulley/damper centre bolt : Use new bolts. Tighten centre bolt to 130 Nm + 40°-50°
Camshaft sprocket/gear : 45 Nm Camshaft/rocker cover : 8 Nm Inlet manifold to cylinder head : 22 Nm Exhaust manifold to cylinder head : 22 Nm Spark plugs : 25 Nm Lambda sensor (Oxygen) : 30 Nm Chassis tightening torques Front hub :

• Tighten nut in three stages:
  1. 130 Nm
  2. Slacken off
  3. 20 Nm + 80°-90°.

Steering track rod end : New nuts 60 Nm Brake disc to hub Front: 4 Nm Brake caliper to carrier Front: 30 Nm Brake caliper/carrier to hub Front: 95 Nm Brake caliper/carrier to hub Rear: 80 Nm New bolts ABS sensor Front: 8 Nm ABS sensor Rear: 15 Nm Road wheels : 110 Nm
There you go pretty much covers everything hope that helps

Measure the thickness of the disc. It could be thin enough with the worn bads that the piston is coming out so far that it is binding in the bore.

the spec is on the drum

They are cast onto the drum.

Brake Pads Removal & Installation Front

To Remove:

1. Drain brake fluid to ½ full level in reservoir.
2. Remove the front wheels.
   
   
3. Remove the front brake caliper assembly.
4. Remove the 2 anti-squeal shims from each of the 2 brake pads.
5. Remove the wear indicator from each of the 2 brake pads.

To Install:
NOTE: When replacing worn pads, the anti-squeal shims must be replaced together with the pads.

1. Using a large C clamp or equivalent press piston into the caliper.
2. Apply disc brake grease to the inside of each anti-squeal shim.
3. Install the anti-squeal shims on each pad.
4. Install the pad wear indicator clip to the pads.
5. Install the pads with the pad wear indicator plate facing upward.
6. Install the brake caliper with the 2 mounting bolts. Torque the bolts 25 ft-lb (34 Nm).
7. Install the front wheels.
8. Fill the master cylinder with new clean brake fluid.
9. Pump the brake pedal several times to seat the brake pads.

Rear TMC made rear brake components

TMMK made rear brake components

To Remove:

1. Drain the brake fluid to ½ full level in reservoir.
2. Remove the rear wheels.
3. Remove the caliper slide pins.
4. Remove the caliper slide pin bushings (TMMK made) (Kentucky).
5. Remove the rear brake calipers.
6. Remove the 2 brake pads with the anti-squeal shims.
7. Remove the anti-squeal shims and pad wear indicators from brake pads.

To Install:

1. Using a large C clamp or equivalent press the piston into the caliper.
2. Coat both sides of the outer anti-squeal shim with pad grease.
3. Install anti-squeal shims to each pad.
4. Install wear indicators on the 2 brake pads.
5. Install the caliper slide pin bushings (TMMK made) (Kentucky).
6. Install the rear brake caliper with the slide pins. Torque the slide pins as follows:
   • TMC made (Japan): Torque the caliper slide pin 25 ft-lb (34.3 Nm)
   • TMMK made (Kentucky): Torque the caliper slide pin 34 ft-lb (47 Nm)
7. Fill the master cylinder with new clean brake fluid.
8. Pump the brake pedal several times to seat the brake pads.
9. Install the rear wheels.

Brake Rotor Removal & Installation Front To Remove:

1. Remove the front wheels.
2. Remove the front brake caliper assembly.
3. Remove the front brake pads.
4. Remove the 2 bolts and caliper mounting bracket.
5. Place match marks on the disc and axle hub.
6. Remove the front wheel disc.

To Install:

1. Align the match marks and install the front disc.
2. Install the brake caliper mounting bracket. Torque the bolts 79 ft-lb (107 Nm).
3. Install the brake caliper. Torque the bolts 25 ft-lb (34 Nm).
4. Install new gaskets and connect the brake hose to the caliper with the banjo fitting bolt. Torque the fitting bolt 22 ft-lb (29.4 Nm).
5. Fill the reservoir with brake fluid.
6. Bleed the brake system.
7. Install the front wheel.

Rear To Remove:

1. Remove the rear wheels.
2. Remove the brake caliper assembly.
3. Remove the brake pads.
4. Remove the 2 bolts and the caliper mounting bracket.
5. Place match marks on the disc and axle hub.
6. Remove the rear disc.

To Install:

1. Align the match marks and install the rear disc.
2. Install the rear brake caliper mounting bracket. Torque the bracket bolts as follows:
   • TMC made (Japan): Torque the bracket bolt 46 ft-lb (61.8 Nm)
   • TMMK made (Kentucky): Torque the bracket bolt 34 ft-lb (47 Nm)
3. Install the rear brake caliper with the slide pins. Torque the slide pins as follows:
   • TMC made (Japan): Torque the caliper slide pin 25 ft-lb (34.3 Nm)
   • TMMK made (Kentucky): Torque the caliper slide pin 32 ft-lb (43 Nm)
4. Install new gaskets and connect the brake hose to the caliper with the banjo fitting bolt. Torque the fitting bolt 22 ft-lb (29.4 Nm).
5. Fill the reservoir with brake fluid.
6. Bleed the brake system.
7. Install the rear wheel

4-Wheel Drive

1. Before servicing the vehicle, refer to the Precautions Section.
   
2. Remove or disconnect the following:
   
   • Negative battery cable
     
   • Rear wheel
     
   • Rear brake shoes
     
   • Rear halfshaft nut and loosen the halfshaft from the hub
     
   • Wheel hub and place it in a vise
     
   • Inner wheel bearing race from the hub
     
   • Antilock Brake System (ABS) sensor bracket and move the sensor aside, if equipped
     
   • Parking brake cable from the steering knuckle
     
   • Brake line from the wheel cylinder and support the knuckle
     
   • Lower shock absorber nut
     
   • Lower ball joint by holding the ball joint stud
     
   • Upper ball joint
     
   • Coil spring while noting the location of the insulator
     
   • Steering knuckle cam
     
   • Steering knuckle
     
   • Snapring and press out the outer wheel bearing race from the knuckle
     

     Rear hub and bearing
     Click to Enlarge

To install:

1. Install or connect the following:
   
   • New wheel bearing into the steering knuckle
     
   • Snapring to the knuckle
     
   • Wheel hub
     
   • Steering knuckle cam and hand tighten the bolt
     
   • Coil spring
     
   • Shock absorber lower nut. Torque the nut to 85 ft. lbs. (115 Nm) for 2002-04 models; 129 ft. lbs. (175 Nm).
     
   • Upper ball joint. Torque the nut to 76 ft. lbs. (103 Nm).
     
   • Lower ball joint. Torque the nut to 76 ft. lbs. (103 Nm). Align the steering knuckle cam and torque the bolt to 85 ft. lbs. (115 Nm).
     
   • Brake line to the wheel cylinder. Torque the brake line bracket bolt to 15 ft. lbs. (20 Nm) and the brake line fastener to 11 ft. lbs. (15 Nm).
     
   • Parking brake cable to the backing plate. Torque the bolt to 16 ft. lbs. (22 Nm).
     
   • ABS sensor bracket. Torque the bolt to 80 inch lbs. (9 Nm), if equipped
     
   • Halfshaft nut. Torque the nut to 214 ft. lbs. (290 Nm).
     
   • Brake shoes
     
   • Rear wheel
     
   • Negative battery cable
     
2. Fill and bleed the brake system.
   
3. Check and adjust the wheel alignment as needed.
   

2-Wheel Drive

1. Before servicing the vehicle, refer to the Precautions Section.
   
2. Remove or disconnect the following:
   
   • Negative battery cable
     
   • Rear wheel
     
   • Rear brake drum
     
   • Wheel hub nut
     
   • Wheel hub
     
   • Inner wheel bearing race from the hub
     
   • Snapring
     
   • Wheel bearing outer race from the knuckle
     

     Rear hub and bearing
     Click to Enlarge

     Rear hub removal
     

     Inner wheel bearing removal-rear hub/bearing
     

     Rear wheel bearing removal-2wd
     

     Rear wheel bearing removal-4wd
     

To install:
Install or connect the following:

• Wheel bearing in to the knuckle
  
• Snapring
  
• Wheel hub into the wheel bearing
  
• Wheel hub nut. Torque the nut to 214 ft. lbs. (290 Nm).
  
• Brake drum
  
• Rear wheel
  
• Negative battery cable
  

  Rear wheel bearing installation
  
  hope this helps if so send testimonial comment or even any other questions you have
  

Front (4 Wheel Drive) To Remove:

1. Raise and support the vehicle
2. Remove or disconnect the following:
   • Tire and wheel assembly
   • Rotor (See: Disc Brake Rotor)
   • Wheel speed sensor and brake hose mounting bracket bolt from the steering knuckle
   • Electrical connection for the wheel speed sensor
   • Front drive halfshaft assembly (See: Halfshaft)
   • Hub and bearing assembly mounting bolts 4WD front hub
     
     
   • Hub and bearing assembly

To Install:

1. Clean all corrosion or contaminates from the steering knuckle bore and the hub and bearing assembly
2. Lubricate the steering knuckle bore with wheel bearing grease or the equivalent
3. Install or connect the following:
   • Hub and bearing assembly
   • Hub and bearing assembly mounting bolts and tighten the hub to knuckle bolts; Torque to: 133 ft. lbs. (180 Nm)
   • Front drive halfshaft assembly (See: Halfshaft)
   • Electrical connection for the wheel speed sensor
   • Wheel speed sensor and brake hose mounting bracket bolt to the steering knuckle and tighten the bolt; Torque to: 106 inch. lbs. (12 Nm)
   • Rotor (See: Disc Brake Rotor
   • Tire and wheel assembly
   Wheel lug nut tightening sequence
   
   
4. Torque the lug nuts to specification
5. Test drive the vehicle to confirm the repairs

Very easy! I owned several different year Windstars....very good van...

Changing the pads are very easy. Here is the instructions:

Removal & Installation

1. Remove the brake master cylinder reservoir cap. Siphon and recycle approximately half the fluid from the reservoir.
   
2. Raise and support the vehicle safely.
   
3. Remove the wheels.
   
4. Remove the disc brake caliper guide pins.
   

It is not necessary to disconnect the hydraulic lines.

1. Lift the disc brake caliper from the anchor plate.
   
2. Position the disc brake caliper out of the way by suspending with a wire.
   
3. Remove the brake pads from the anchor plate.
   

To install:

1. Inspect the rotor surfaces for scoring or buildup of lining material. Minor imperfections do not require machining. Hand sand the glaze from the rotor using 150 grit aluminum oxide sand paper.
   
2. Use a C-clamp and wooden block to seat the disc brake caliper hydraulic piston in its bore, as illustrated. This must be done to provide clearance for the disc brake caliper to fit over the front rotor during installation.
   
3. Remove all built-up rust from the inside of the brake caliper pad contact area.
   
4. Install the brake pads, with the clip on insulators, into the front brake caliper anchor plate.
   
5. Install the disc brake caliper onto the anchor plate.
   
6. Install the disc brake caliper guide pins and tighten to 23-38 ft. lbs. (31-38 Nm).
   

Failure to tighten the lug nuts to the proper torque in a star pattern may result in damage to the brake rotor.

1. Install the wheel and tighten lug nuts to 83-112 ft. lbs. (113-153 Nm).
   
2. Lower the vehicle.
   
3. Pump the brake pedal to seat the brake pads.
   

Atention!!!
Don't disconnect any brake line from caliper!
Don't disconnect any ABS sensor!
For change front brake pads you must raise vehicle, remove wheels, extract the retaining spring of the caliper, and remove the caliper as follow: 1. Do not disconnect the brake hose from the caliper, and do not allow the caliper to hang by the brake hose! 2. Remove top and bottom caps (on back side of the caliper) for access to guide pins, then unbolt and remove them from the brake carrier. Remove the caliper. 3. Now you must thoroughly clean the brake calipers (free of grease). 4. Remove outer brake pad from brake carrier. 5. Pull inner brake pad out of brake caliper piston. 6. Remove brake carrier from wheel bearing housing (two ribbed bolts). 125 Nm 7. Remove brake disc from wheel hub. 8. Install brake carrier on wheel bearing housing. Tightening torque for two ribbed bolts = 125 Nm. 9. Check up the brake fluid level on the reservor, and emptying if neccessary! 10. Push piston back into brake caliper housing. 11. Install inner brake pad (with expanding spring) in brake caliper piston. (Arrow marked on pad - if exist, must point in direction of brake disc rotation when vehicle is moving forward). 12. Install outer brake pad into brake carrier. 13. Bolt brake caliper housing to brake carrier using two guide pins. Tightening torque is 25 Nm. 14. Install both caps. 15. Insert retaining spring into brake caliper housing. Important: Depress the brake pedal firmly several times while the car is stationary so that the brake pads adjust to their normal operating positions!!! Check brake fluid level and top up if neccessary!!! Please Rate my Response! Thanks!