Section 06-04: Brakes, Rear Disc
1996 F-Super Duty Workshop Manual
REMOVAL AND INSTALLATION

Brake Shoe and Lining

Removal

  1. Remove sufficient brake fluid from the brake master cylinder reservoir (2K478) to allow for compressing the caliper pistons (2196) into the disc brake caliper bore.

  1. Raise and support the vehicle.

  1. Remove the tire and wheel assembly.

  1. Position an appropriate C-clamp on the disc brake caliper (2B120), with the clamp frame on the caliper and the clamp screw on the outboard brake shoe and lining backing plate.

  1. Compress the C-clamp to drive the caliper pistons into the caliper bore only enough to provide removal clearance. Remove the C-clamp.

  1. Using Hydraulic Caliper Pin Remover D89T-2196-A or equivalent, drive out the upper and lower caliper locking pins.

  1.  CAUTION: Do not allow the disc brake caliper to hang from the rear brake hose.

    Tilt out and remove the disc brake caliper from the support bracket. Support the disc brake caliper with a wire or equivalent.

  1. Remove the brake shoes and linings (2001) from the disc brake caliper support bracket.

Installation

  1.  WARNING: CONTAMINATED BRAKE SHOES AND LININGS CAN SEVERELY AFFECT BRAKING EFFICIENCY. DO NOT INSTALL BRAKE SHOES AND LININGS CONTAMINATED BY GREASE, OIL OR BRAKE FLUID. DO NOT ATTEMPT TO CLEAN CONTAMINATED BRAKE SHOES AND LININGS.

    Position the brake shoes and linings and anti-rattle clips in the disc brake caliper support bracket.

  1. Position the disc brake caliper into the disc brake caliper support bracket.

  1. Lubricate the caliper locking pins with Ford Silicone Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or equivalent meeting Ford specification ESE-M1C171-A.

  1. Drive the caliper locking pins into the caliper/support bracket assembly.

  1. Replace the tire and wheel assembly. Tighten the lug nuts (1012) to 190 Nm (140 lb-ft).

  1. Lower the vehicle.

  1. NOTE: Check and maintain the brake fluid at sufficient level to prevent air from entering the system.

    Operate the brake pedal (2455) several times to bring the caliper pistons into contact with the brake shoe and lining.

  1. 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.

  1. Test the brake system for proper operation.