Section 06-03: Brakes, Front Disc | 1996 F-150, F-250, F-350 4x2, 4x4, Bronco and F-Super Duty Vehicles Workshop Manual |
The ends of the brake shoes and linings (2001) are contained within the spindle. The spindle abutments on each end provide a low drag surface for the pads to slide against. The brake caliper mounts over the top of the pads.
Disc Brake, F-250 (Above 6900 GVWR), F-350 4x2
| Item | Part Number | Description |
|---|---|---|
| 1 | N807794-S60 | Bolt, M16-2.0 x 50 |
| 2 | 2B120 | Disc Brake Caliper (RH) |
| 3 | 2B121 | Front Disc Brake Caliper (LH) |
| 4 | 2B160 | Front Brake Splash Shield Gasket |
| 5 | N611171-S2 | Screw, M6-1.0 x 10 |
| 6 | 1190 | Wheel Hub Grease Seal |
| 7 | 1216 | Front Wheel Bearing |
| 8 | 1195 | Front Wheel Outer Bearing Retainer Washer |
| 9 | N642569-S36 | Cotter Pin |
| 10 | 1131 | Hub Grease Cap |
| 11 | 390622-S | Nut Retainer |
| 12 | 374504-S100 | Nut, 3/4-16 |
| 13 | 1102 | Front Disc Brake Hub and Rotor |
| 14 | 4221 | Front Wheel Inner Bearing Cone and Roller Assembly |
| 15 | 2K004 | Front Disc Brake Rotor Shield (RH) |
| 16 | 2K005 | Front Disc Brake Rotor Shield (LH) |
| 17 | 3105 (RH) | Front Wheel Spindle Assembly |
| 18 | 3106 (LH) | Front Wheel Spindle Assembly |
| A | — | Tighten to 191-259 Nm (141-190 Lb-Ft) |
| B | — | Tighten to 9-13 Nm (80-115 Lb-In) |
| C | — | Tighten to 23-34 Nm (17-25 Lb-Ft) while rotating rotor counterclockwise. Back off nut 120-180 degrees. Use torque wrench set to tighten nut 2.03-2.26 Nm (18-20 Lb-In). End play to be 0.006-0.127mm (0.00025-0.005 in.). Position nut retainer 390622-S over nut so that a slot in the retainer lines up with the cotter pin hole in the spindle. The adjusting nut must not be rotated while installing retainer. Insert cotter pin and secure by bending the legs in opposite directions around the nut retainer. |
Disc Brake System, F-250, F-350 4x4
| Item | Part Number | Description |
|---|---|---|
| 1 | 2B120 | Disc Brake Caliper (RH) |
| 2 | 2B121 | Front Disc Brake Caliper (LH) |
| 3 | N807794-S60 | Bolt, M16-2.0 x 53 |
| A | — | Tighten to 191-259 Nm (141-191 Lb-Ft) |
Sliding Caliper Disc Brake Installation, F-150 4x2
| Item | Part Number | Description |
|---|---|---|
| 1 | N807683-S60 | Bolt, M8 x 1.25 x 65 |
| 2 | 2B120 | Disc Brake Caliper (RH) |
| 3 | 2B121 | Front Disc Brake Caliper (LH) |
| 4 | 2068 | Brake Shoe Hold-Down Springs |
| 5 | N611171-S2 | Screw, M6-1.0 x 10 |
| 6 | 1190 | Wheel Hub Grease Seal |
| 7 | 1102 | Front Disc Brake Hub and Rotor |
| 8 | 1216 | Front Wheel Bearing |
| 9 | 1195 | Front Wheel Outer Bearing Retainer Washer |
| 10 | N642569-S36 | Cotter Pin |
| 11 | 1131 | Hub Grease Cap |
| 12 | 390622-S | Nut Retainer |
| 13 | 374504-S100 | Nut, 3/4-16 |
| 14 | 1012 | Lug Nut |
| 15 | 1201 | Bearing Cone and Roller |
| 16 | 2K004 | Front Disc Brake Rotor Shield (RH) |
| 17 | 2K005 | Front Disc Brake Rotor Shield (LH) |
| 18 | 2B160 | Front Brake Splash Shield Gasket |
| 19 | 3105 | Front Wheel Spindle (RH) |
| 20 | 3106 | Front Wheel Spindle (LH) |
| A | — | Tighten to 30-36 Nm (22-27 Lb-Ft) |
| B | — | Tighten to 9-13 Nm (80-115 Lb-In) |
| C | — | Tighten to 23-34 Nm (17-25 Lb-Ft) while rotating rotor counterclockwise. Back off nut 120-180 degrees. Use torque wrench set to tighten nut to 2.03-2.26 Nm (18-20 Lb-In). End play to be 0.006-0.127mm (0.53-1.1 inch). Position nut retainer 390622-S over nut so that a slot in the retainer lines up with the cotter pin hole in the spindle. The adjusting nut must not be rotated while installing retainer. Insert cotter pin and secure by bending the legs in opposite directions around the nut retainer. |
Sliding Caliper Disc Brake Installation, F-150 and Bronco 4x4 with Automatic Locking Hubs
| Item | Part Number | Description |
|---|---|---|
| 1 | N807683-S60 | Bolt, M8-1.25 x 65 |
| 2 | 2B120 | Disc Brake Caliper (RH) |
| 3 | 2B121 | Front Disc Brake Caliper (LH) |
| 4 | 2K004 | Front Disc Brake Rotor Shield (RH) |
| 5 | 2K005 | Front Disc Brake Rotor Shield (LH) |
| 6 | 3299 | Integral Spacer Needle Bearing Seal |
| 7 | 3123 | Caged Needle Bearing |
| 8 | 3105 | Front Wheel Spindle |
| 9 | 3254 | Spindle Rolling Diaphragm Seal |
| 10 | 1190 | Wheel Hub Grease Seal |
| 11 | 4221 | Wheel Bearing (Inner) |
| 12 | 4222 | Bearing Cup |
| 13 | 1125 | Front Disc Brake Rotor |
| 14 | 1104 | Wheel Hub |
| 15 | — | Wheel Retainer (Nut) (Part of 1K105) |
| 16 | 4221 | Wheel Bearing (Outer) |
| 17 | 4222 | Bearing Cup |
| 18 | 35704 | Dana Nut |
| A | — | Tighten to 30-36 Nm (22-27 Lb-Ft) |
Sliding Caliper Disc Brake, F-150 4x4 and Bronco with Manual Locking Hubs
| Item | Part Number | Description |
|---|---|---|
| 1 | N807683-S60 | Bolt, M8-1.25 x 65 |
| 2 | 2B120 | Disc Brake Caliper (RH) |
| 3 | 2B121 | Front Disc Brake Caliper (LH) |
| 4 | 2K004 | Front Disc Brake Rotor Shield (RH) |
| 5 | 2K005 | Front Disc Brake Rotor Shield (LH) |
| 6 | 3299 | Integral Spacer Needle Bearing Seal |
| 7 | 3123 | Caged Needle Bearing |
| 8 | 3105 | Front Wheel Spindle |
| 9 | 3254 | Spindle Rolling Diaphragm Seal |
| 10 | 1190 | Wheel Hub Grease Seal |
| 11 | 4221 | Wheel Bearing (Inner) |
| 12 | 4222 | Bearing Cup |
| 13 | 1125 | Front Disc Brake Rotor |
| 14 | 1104 | Wheel Hub |
| 15 | 1197 | Lock Nut (Outer) |
| 16 | 1198 | Lockwasher |
| 17 | 1195 | Lock Nut (Inner) |
| 18 | 4221 (Outer) | Wheel Bearing |
| 19 | 4222 | Bearing Cup |
| 20 | 35704 | Dana Nut |
| A | — | Tighten to 30-36 Nm (22-27 Lb-Ft) |
Disc Brake System, F-150 4x4 and Bronco
