Section 06-03: Brakes, Front Disc
1996 F-150, F-250, F-350 4x2, 4x4, Bronco and F-Super Duty Vehicles Workshop Manual
REMOVAL AND INSTALLATION

Brake Shoe and Lining

Dual Piston

Replace brake shoes and linings (2001) as follows when the lining is worn to a minimum thickness of 0.794mm (1/32 inch) above the brake backing plate (2211).

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

Removal

  1. Remove disc brake caliper.

  1. Remove the outer and inner lining.

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

Installation

  1. Install new inner and outer lining.

  1. Install disc brake caliper.

Single Piston

Removal

Replace brake shoes and linings as follows when the lining is worn to a minimum thickness of 1.5mm (1/16 inch) above the shoe plate.

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

  1. To avoid fluid overflow when the caliper piston is 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.

  1. NOTE: Do not use a screwdriver or similar tool to pry caliper piston (2196) away from the front disc brake hub and rotor (1102).

    Remove disc brake caliper.

  1. Remove the inner and outer linings by sliding them out from beneath the brake shoe hold-down spring (2068).

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

Installation

  1. Lubricate the knuckle upper and lower abutments with Disc Brake Caliper Slide Grease, Silicone Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to prevent corrosion buildup between the brake shoe hold-down spring and the knuckle.

  1. Install the brake shoe hold-down spring by placing the lower edge of the clip beneath the abutment surface of the knuckle and rotating the clip up into position. Press against the slide surfaces of the clip to make sure the clip is tightly seated on the knuckle.

  1. Position the inner shoe against the front disc brake hub and rotor so that it is caught by the brake shoe hold-down spring. To do this, slide the shoe past the knuckle tabs and wedge one end into position against the brake shoe hold-down spring. While lifting the top spring portion of the other brake shoe hold-down spring, slide the pad onto the abutment and against the front disc brake hub and rotor.

  1. Install the outer shoe in the same manner.

  1. Replace disc brake caliper.