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

Caliper

 

Disassembly

  1. Remove the front disc brake caliper (2B120) from the vehicle. Refer to Caliper in the Removal and Installation portion of this section.

    ItemPart NumberDescription
    12120Piston Boot
    22120Piston Seal
    32B120Disc Brake Caliper
    42068Brake Shoe Hold-Down Spring
    52001Brake Shoe and Lining
    62208Bleeder Screw
    72196Caliper Piston

  1. Open the bleeder screw and drain any remaining brake fluid from the disc brake caliper. After draining the fluid, close the bleeder screw.

  1. Position a block of wood between the disc brake caliper and the caliper pistons (2196).

  1.  WARNING: DO NOT USE AN EXCESSIVE AMOUNT OF AIR PRESSURE TO REMOVE THE CALIPER PISTONS. EXCESSIVE PRESSURE CAN FORCE THE CALIPER PISTONS OUT OF THE DISC BRAKE CALIPER BORE WITH ENOUGH FORCE TO CAUSE PERSONAL INJURY. NEVER ATTEMPT TO CATCH THE CALIPER PISTONS BY HAND AS THEY COME OUT OF THE DISC BRAKE CALIPER BORE.

    NOTE: Apply only enough air pressure to ease the caliper pistons out of the disc brake caliper.

    Apply air pressure through the rear brake hose fitting to remove the caliper pistons.

  1. Remove the caliper pistons.

  1. Remove and discard the dust seal.

  1.  CAUTION: Use a plastic or wooden pick to remove the piston seal. Do not use a metal tool. A metal tool can scratch or nick the piston seal groove and result in a possible piston seal leak.

    Use a pick to remove the piston seal from the piston bore. Discard the piston seal.

Assembly

SPECIAL SERVICE TOOL(S) REQUIRED
DescriptionTool Number
Piston Dust Seal ReplacerT92P-2588-AH
Driver HandleT80T-4000-W

  1. Inspect the disc brake caliper and caliper pistons for cracks or other damage. Replace as necessary.

  1.  CAUTION: Do not hone disc brake caliper bores. Replacement caliper pistons and seals are not available for honed caliper bores.

    Lubricate the caliper bore and a new piston seal with Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AA or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A.

  1. Install the new piston seal in the caliper bore.

  1. Install a new dust boot on one caliper piston.

  1.  CAUTION: Use care not to scratch or damage the caliper piston when installing it into the caliper bore.

    Using care not to dislodge or distort the piston seal, install the caliper piston into the caliper bore.

  1. Use Piston Dust Seal Replacer T92P-2588-AH and Driver Handle T80T-4000-W to seat the new dust boot into the disc brake caliper.

  1. Repeat Steps 2, 3, 4, 5 and 6 for the other caliper piston.

  1. Install the disc brake caliper in the vehicle. Refer to Caliper in the Removal and Installation portion of this section.

  1. Bleed the brake system. Refer to Section 06-06.

  1. Test the brakes for proper operation.