Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2002 Ford ZX2 AutomaticFACTORY OEM SERVICE PROCEDURE
General Specifications
GENERAL SPECIFICATIONS CHART
| Item | Specification |
|---|---|
| Brake Pedal | |
| Pedal Height mm (in) | 193-196 (7.60-7.72) |
| Pedal Free Play mm (in) | 4-12 (0.16-0.47) |
| Pedal-to-Floor Clearance mm (in) | 70 (2.76) |
| Brake Pads | |
| Brake pad minimum thickness | 3.0 mm (0.118 inch) |
| Brake pad maximum thickness variation (pad-to-pad) | 2.0 mm (0.079 inch) |
| Brake pad maximum taper wear (in any direction) | 3.0 mm (0.118 inch) |
| Brake Disc | |
| Front brake disc minimum thickness | 20.0 mm (0.78 inch) |
| Rear brake disc minimum thickness | 8.0 mm (0.31 inch) |
| Minimum thickness to machine front brake disc | 20.6 mm (0.81 inch) |
| Minimum thickness to machine rear brake disc | 8.6 mm (0.33 inch) |
| Brake Drum | |
| Maximum inside diameter | 230.0 mm (9.05 inch) |
| Lubricant | |
| High Performance DOT 3 Motor Vehicle Brake Fluid PM -1 (Canada CXC-31) | ESA-M6C25-A (United States and Canada only) |
| High Performance DOT 4 Brake Fluid | - |
| High Temperature Nickel Anti-Seize Lubricant XL-2 (Canada CXG-2-B) | ESE-M12A4-A |
| Silicone Brake Caliper Grease and Dielectric Compound XG-3 | ESE-M1C171-A |
| Brake Parts Cleaner PM -4 | - |
Factory Service Tools
Use the Manual With the Right Hardware
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.
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