Section 06-04: Brakes, Rear Disc | 1996 F-Super Duty Workshop Manual |
Removal
Remove sufficient brake fluid from the brake master cylinder reservoir (2K478) to allow for pressing the caliper pistons (2196) into the bore. Discard the brake fluid.
Raise and support the vehicle.
Remove the wheel (1007).
| Item | Part Number | Description |
|---|---|---|
| 1 | 2B292 | Disc Brake Caliper Support Bracket |
| 2 | 2208 | Bleeder Screw |
| 3 | 385116-S2 | Rear Brake Hose-to-Caliper Flow Bolt |
| 4 | 2B120 | Disc Brake Caliper |
| 5 | 2C150 | Caliper Locking Pin, Lower |
| 6 | 2001 | Brake Shoe and Lining, Outboard |
| 7 | — | Anti-Rattle Clip (Part of 2001) |
| 8 | 1109 | Rear Hub and Rotor Assembly |
| 9 | 2C150 | Caliper Locking Pin, Upper |
| A | — | Tighten to 7-9 Nm (62-80 Lb-In) |
| B | — | Tighten to 30-39 Nm (22-29 Lb-Ft) |
Position an appropriate C-clamp on the disc brake caliper (2B120), with the clamp frame on the disc brake caliper and the clamp screw on the outboard brake shoe and lining backing plate.
Compress the C-clamp to drive the caliper pistons into the caliper bore only enough to give removal clearance. Remove the C-clamp.
Remove the rear brake hose-to-caliper flow bolt and discard the copper washers.
Plug the rear brake hose to prevent brake fluid loss and air entry.
Using Hydraulic Caliper Pin Remover D89T-2196-A or equivalent, drive out the upper and lower caliper locking pins.
Remove the disc brake caliper from the vehicle.
Installation
If necessary, install the brake shoe and lining (2001) and anti-rattle clip.
Position the disc brake caliper in the support bracket.
Lubricate the caliper locking pins with Ford Silicone Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or equivalent meeting Ford specification ESE-M1C171-A.
Drive the caliper locking pins into the caliper/support bracket assembly until the tabs at each end of the pin snap into place.
Using new copper washers, attach the rear brake hose to the disc brake caliper. Tighten the rear brake hose-to-caliper flow bolt to 30-39 Nm (22-29 lb-ft).
Replace the wheel and tire assembly. Tighten the lug nuts (1012) to 190 Nm (140 lb-ft).
Lower the vehicle.
NOTE: Check the brake fluid level in the brake master cylinder reservoir and maintain sufficient level to prevent air entry into the system.
Pump the brake pedal (2455) several times to drive the caliper pistons into contact with the brake shoe and lining.
Fill the brake master cylinder reservoir with Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AA or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A.
Bleed the brake system and test the brakes for proper operation. Refer to Section 06-06.