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

Rotor

Removal

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

    Raise the front of the vehicle and install safety stands.

  1. Remove the wheel (1007) and tire assembly.

  1. Remove both anchor bolts. Examine both bolts for damage.

  1. Remove the disc brake caliper from the front disc brake hub and rotor (1102) and hold it out of the way with wire. Refer to Caliper Removal in this section.

  1. Remove the dust cap, cotter pin, lock nut, bearing retaining nut, washer, and outer bearing, and remove the front disc brake hub and rotor from the front wheel spindle. Refer to the appropriate axle section in Group 05 for the vehicle being serviced.

  1. Check the condition of the front disc brake hub and rotor. Refer to Section 06-00.

  1. Remove bearing cone and roller (1201). Discard the seal.

  1. On F-Super Duty, the front disc brake rotor (1125) can be removed from the wheel hub (1104) by removing the 10 M 12 x 1.75 x 32.50mm E-18 external Torx® machine screws.

Installation

  1. If installing a new front disc brake hub and rotor, remove the protective coating or any dirt or grease deposits with degreaser. On F-Super Duty vehicles, the machine screw threads must be coated with a suitable adhesive before attaching the front disc brake rotor to the wheel hub. Tighten screws to 100-120 Nm (74-89 lb-ft).

  1. Thoroughly clean the bearing cone and rollers. Inspect for damage or wear. Refer to Section 04-00 for bearing diagnosis. Replace if necessary.

  1. Pack the front wheel bearing (1216) and bearing cone and roller with a lithium-base grease such as Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B.

  1. Install the bearing cone and roller. Refer to Section 04-01A for 4x2 or Section 04-01B for 4x4 procedures.

  1. Install the front disc brake hub and rotor on the front wheel spindle (3105).

  1. Install the front wheel bearing, washer and nut.

  1. Adjust bearing end play and install the lock nut, cotter pin and dust cap as described in Section 04-01A.

  1. Install the disc brake caliper and anchor assembly by installing two bolts. Tighten both bolts to the appropriate specification.

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

  1. Lower the vehicle. Check brakes for proper operation.