Caliper

Heavy-Duty Rail Slider, F-Super Duty

Replace brake shoe and lining (2001) as follows when the lining is worn to a minimum thickness of 0.794mm (1/32 inch) above the front disc brake rotor shield.

 CAUTION: Always replace all brake shoes and linings on an axle. Never replace only one wheel (1007).

Removal

1. To avoid fluid overflow when the caliper pistons are pressed into the caliper cylinder bores, siphon or dip part of the brake fluid out of the brake master cylinder reservoir (2K478). Discard the removed fluid.

2. Raise the vehicle and install safety stands. Remove the front wheel and tire assembly.

3. Place an appropriate size C-clamp on the disc brake caliper with end of clamp against caliper and end of screw against outer shoe. Tighten the clamp to bottom the caliper pistons in the cylinder bores. Remove the clamp. Do not use a screwdriver or similar tool to pry caliper pistons (2196) away from the front disc brake rotor (1125).

   

4. Clean excess dirt from area around pin tabs.

5. Tap upper caliper pin toward inboard side until pin tabs touch the front wheel spindle.

6. Using Hydraulic Caliper Pin Remover D89T-2196-A or equivalent and a light hammer, drive the pin from the disc brake caliper as follows:

   1. Position the notched end of the tool against the caliper pin (retention tab half), at a 45-degree angle from the pin retention tabs.

      

   2. Tap the tool with the hammer to compress the retention tabs.

      

   3. As the retention tabs are compressed, move the tool to gain a straight approach to the caliper pin, and continue tapping to drive the caliper pin through the caliper/spindle groove.

7. Repeat removal procedure for lower caliper pin.

8.  CAUTION: Do not let the disc brake caliper hang by the front brake hose (2078). The front brake hose could become stretched or twisted which can cause the front brake hose to leak and rupture, resulting in failure.

   Remove the disc brake caliper from the front disc brake rotor. If the disc brake caliper is to be removed for service, remove the front brake hose from the disc brake caliper. Plug the end of the front brake hose to prevent fluid loss and entry of air into the system. If the disc brake caliper is not to be removed, wire it up to the frame of the vehicle to avoid damage to the front brake hose.

Installation

 CAUTION: Always replace all brake shoes and linings on an axle. Never replace only one wheel.

1. NOTE: There is a raised section at one end of each shoe so installation can be made in one direction only.

   Install new inner and outer lining.

2. Lubricate the knuckle upper and lower inner pad grooves and caliper grooves with Disc Brake Caliper Slide Grease, Silicone Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A. Install the disc brake caliper on a front wheel spindle, making sure the mounting surfaces are free of dirt.

3.  CAUTION: Do not allow the tabs of the caliper pin to be tapped too far into the spindle groove. If this happens it will be necessary to tap the other end of the caliper pin until the tabs snap into place. The tabs on each end of the caliper pin must be free to catch on the spindle flanks.

   Position caliper pin with the pin retention tabs oriented adjacent to the spindle groove.

4. Tap the caliper pin on the outboard end with a hammer. Continue tapping the caliper pin inward until the retention tabs on the sides of the caliper pin contact the spindle face. Repeat procedure for the lower caliper pin.

   

5. If removed, install the front brake hose to the disc brake caliper and bleed the disc brake calipers as described in Section 06-00.

6. Install the wheel and tire. Tighten the lug nuts (1012). Refer to Specifications at the end of this section.

7. Lower the vehicle, check the brake fluid level and fill as necessary. Check disc brake calipers for proper operation.

Heavy-Duty Pin Slider, F-250, F-350

Removal

1. To avoid fluid overflow when the caliper pistons are pressed into the caliper cylinder bores, siphon or dip part of the brake fluid out of the brake master cylinder reservoir. Discard the removed fluid.

2. NOTE: When raising the vehicle make sure the hoist lift points do not rest on the caliper pins.

   Raise the vehicle on a hoist and install safety stands. Remove the wheel and tire.

3. NOTE: Do not use a screwdriver or similar tool to pry the caliper piston away from the front disc brake hub and rotor.

   Place an appropriate size C-clamp on the disc brake caliper with end of clamp against caliper and end of screw against outer shoe. Tighten the clamp to bottom the caliper pistons in the cylinder bores. Remove the C-clamp.

   

   Item	Part Number	Description
   1	2B292	Anchor Bracket
   2	N807794-S60	Anchor Bolt, M16 x 2.0 x 50 (2 Req'd)
   3	2078	Front Brake Hose
   4	2B121	Disc Brake Caliper
   5	—	C-Clamp

4. Remove both caliper slide pins. Examine the slide pins and caliper pin insulators to assure that they are not damaged. Replace if necessary.

   

   Item	Part Number	Description
   1	2B292	Anchor Bracket
   2	N807794-S60	Anchor Bolt, M16 x 2.0 x 50 (2 Req'd)
   3	—	Caliper Pin (Part of 2B120)
   4	2B120	Disc Brake Caliper
   5	2078	Front Brake Hose

5.  CAUTION: Do not let the disc brake caliper hang by the front brake hose. The front brake hose could become stretched or twisted, which can cause the front brake hose to leak and rupture, resulting in failure.

   Remove the disc brake caliper.

6. If the disc brake caliper is to be removed for repair or replacement, disconnect the front brake hose from the disc brake caliper. Plug the end of the front brake hose to prevent fluid loss and the entry of air into the system. If the disc brake caliper is not to be removed, wire it up to the frame (5005) of the vehicle to avoid damage to the front brake hose.

7. Inspect disc brake caliper. Refer to Cleaning and Inspection in this section.

   

   Item	Part Number	Description
   1	2078	Front Brake Hose
   2	2B120	Disc Brake Caliper
   3	2B292	Anchor Bracket
   4	1102	Front Disc Brake Hub and Rotor

Installation

1. Install caliper slide pins through disc brake caliper and front wheel spindle (3105). Tighten bolts to 191-259 Nm (141-190 lb-ft).

2. If front brake hose was removed, replace both washers (each side of inlet block). Connect the front brake hose. Tighten inlet block bolt to 14-20 Nm (10-15 lb-ft). Bleed the system as described in Section 06-06.

   

3. Install wheel and tire assembly. Remove the safety stands and lower the vehicle.

4. If the brakes were not bled and disc brake caliper was not removed, check the fluid level in the brake master cylinder reservoir and fill if required.

5. Pump the brakes several times to make sure you get a firm brake pedal (2455).

6. Operate the vehicle to check brake operation.

Light-Duty Pin Slider, F-150, Bronco

Removal

1. Raise the vehicle and install safety stands. Remove a front wheel and tire assembly.

2. Remove caliper retaining bolts.

3. Remove the disc brake caliper from the front disc brake hub and rotor (1102). Remove the disc brake caliper by lifting it away from the wheel end. A screwdriver may be required to pry up lightly on the outer shoe clip to free the caliper from the clip.

4.  CAUTION: Do not let the disc brake caliper hang by the front brake hose. The front brake hose could become stretched or twisted, which can cause the front brake hose to leak or rupture, resulting in failure.

   If the disc brake caliper is to be removed for service, remove the front brake hose from the disc brake caliper. Plug the end of the front brake hose to prevent fluid loss or entry of air into the system. If the disc brake caliper is not going to be removed, wire it up to the vehicle to avoid damage to the front brake hose.

5. Inspect disc brake caliper. Refer to Cleaning and Inspection in this section.

Installation

1. Using an 8-inch C-clamp and a block of wood (or equivalent) to protect the piston face, bottom the caliper piston in the caliper bore to provide adequate clearance when installing the disc brake caliper.

2.  CAUTION: Be careful not to scrape the slide pin boots across the knuckle tabs as this could damage the pin assemblies which could eventually result in corrosion on the pin, impeding slide forces and causing a brake pull.

   Install the disc brake caliper by pulling back the slide pins and placing the disc brake caliper over the pads and sliding it down into the outer brake shoe clip, making sure the tips of the brake shoe clip are seated in the retention holes of the disc brake caliper.

3. Install the caliper mounting bolts to secure the disc brake caliper in place. Tighten the bolts to 30-36 Nm (22-27 lb-ft).

4. If removed, install the front brake hose to the disc brake caliper and bleed the brakes as described in Section 06-06.

5. Install the wheel and tire assembly. Tighten the lug nuts. Refer to Specifications at the end of this section.

6. NOTE: Do not move the vehicle until a firm brake pedal application is obtained.

   Lower the vehicle, check the brake fluid level and fill as necessary. Check brakes for proper operation.