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    Ford Pick-Ups/Bronco 1976-1986 Repair Guide

    Disc Brake Pads

    Print

    INSPECTION



    Remove the brake pads as described below and measure the thickness of the lining. If the lining at any point on the pad assembly is less 0.0625 inch; ( 1 / 16 inch; 1.5mm) for LD brakes or 0.03125 inch; ( 1 / 32 inch; 0.794mm) for HD brakes, thick (above the backing plate or rivets), or there is evidence of the lining being contaminated by brake fluid or oil, replace the brake pad.

    REMOVAL & INSTALLATION



    NEVER REPLACE THE PADS ON ONE SIDE ONLY! ALWAYS REPLACE PADS ON BOTH WHEELS AS A SET!

    1976-83 with LD Sliding Caliper (Single Piston)

    See Figures 1 through 20

    1. To avoid overflowing of the master cylinder when the caliper pistons are pressed into the caliper cylinder bores, siphon or dip some brake fluid out of the larger reservoir.
    2.  
    3. Jack up the front of the vehicle and remove the wheels.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 1: Bottom the piston in the cylinder bore with a C clamp



    Click image to see an enlarged view

    Fig. Fig. 2: Removing the caliper support key retaining screw



    Click image to see an enlarged view

    Fig. Fig. 3: Driving out the caliper support key with a drift



    Click image to see an enlarged view

    Fig. Fig. 4: Removing the outer shoe and lining



    Click image to see an enlarged view

    Fig. Fig. 5: Removing the inner shoe and lining



    Click image to see an enlarged view

    Fig. Fig. 6: Assembled view of the LD sliding caliper front brake assembly, 1983 shown



    Click image to see an enlarged view

    Fig. Fig. 7: Removing the caliper support key retaining screw, 1983 shown



    Click image to see an enlarged view

    Fig. Fig. 8: Driving out the caliper support key with a drift, 1983 shown



    Click image to see an enlarged view

    Fig. Fig. 9: Support the caliper assembly with a wire, 1983 shown



    Click image to see an enlarged view

    Fig. Fig. 10: Removing the outer shoe and lining, 1983 shown

    1. Dip out a part of the fluid from the larger portion of the master cylinder.
    2.  
    3. Jack up the front of the vehicle and support it on jackstands.
    4.  
    5. Remove the front wheel.
    6.  
    7. Using an 8 inch; (203mm) C-clamp, bottom the caliper piston by positioning the fixed end of the clamp against the inner side of the caliper and tightening the clamp against the outer pad.
    8.  
    9. Remove the clamp. Remove the key retaining screw.
    10.  
    11. Using a brass drift and light hammer, drive out the caliper support key, and caliper support spring.
    12.  
    13. It is not necessary to disconnect the brake hose.
    14.  
    15. Remove the caliper from its support assembly by pushing downward toward the spindle and rotating the upper end upward and out of the spindle assembly. Support the caliper with a length of wire so that no stress is placed upon the brake hose.
    16.  
    17. Remove the outer pad. It may be necessary to tap it loose. Remove the inner pad and anti-rattle clip.
    18.  
    19. Clean and inspect the caliper assembly.
    20.  

    To install:
    1. Place a new anti-rattle clip on the lower end of the inner pad. Be sure that the clip tabs are positioned properly and that the clip is fully seated.
    2.  
    3. Place the inner pad in the caliper, with the loop type spring of the clip away from the rotor.
    4.  
    5. Place the outer pad in the caliper. Press the tabs into place with fingers or a C-clamp.
    6.  
    7. Place the caliper on the spindle by pivoting it around the support upper mounting surface. Be careful not to tear the boot as it slips over the inner pad.
    8.  
    9. Use a screwdriver to hold the upper machined surface of the caliper against the surface of the support assembly, and install a new caliper support spring and key assembly. Drive the key and spring into position with a plastic mallet. Install the key retaining screw and tighten to 20 ft.lb.
    10.  
    11. When pads have been installed on both front wheels, lower the vehicle and check the fluid level in the master cylinder. Fill as necessary.
    12.  
    13. Depress the pedal several times until a firm pedal is achieved. Do not drive the vehicle until the pedal is firm.
    14.  



    Click image to see an enlarged view

    Fig. Fig. 11: Installing the anti-rattle clip on the inner shoe



    Click image to see an enlarged view

    Fig. Fig. 12: Installing the inner shoe and anti-rattle clip



    Click image to see an enlarged view

    Fig. Fig. 13: Installing the outer shoe and lining



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    Fig. Fig. 14: Holding the upper machined surface of the spindle assembly in preparation for installing the caliper support spring and key



    Click image to see an enlarged view

    Fig. Fig. 15: Assembling the caliper spring and key



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    Fig. Fig. 16: Installation of the caliper support spring and key



    Click image to see an enlarged view

    Fig. Fig. 17: Lightly lubricate the sliding portion of the caliper with brake caliper grease, 1983 shown



    Click image to see an enlarged view

    Fig. Fig. 18: Positioning the caliper assembly on the spindle, 1983 shown



    Click image to see an enlarged view

    Fig. Fig. 19: Inserting the caliper support spring and key, 1983 shown



    Click image to see an enlarged view

    Fig. Fig. 20: Installing the caliper support spring and key, 1983 shown

    1984-86 with LD Sliding Caliper (Single Piston)

    The LD Light Duty sliding caliper disc brake assembly is used on the F-150, F-250 below 6900 GVWR and Bronco.

    See Figures 21 through 26



    Click image to see an enlarged view

    Fig. Fig. 21: Bottoming the caliper piston



    Click image to see an enlarged view

    Fig. Fig. 22: Compressing the pin tabs



    Click image to see an enlarged view

    Fig. Fig. 23: Installing the anti-rattle clip on the inner shoe



    Click image to see an enlarged view

    Fig. Fig. 24: Installing the inner shoe and the anti-rattle clip



    Click image to see an enlarged view

    Fig. Fig. 25: Caliper pin installation



    Click image to see an enlarged view

    Fig. Fig. 26: Correct caliper pin installation

    1. Place an 8 inch; (203mm) C-clamp on the caliper and tighten the clamp to bottom the caliper piston in the cylinder bore. Remove the C-clamp.
    2.  
    3. Clean the excess dirt from around the caliper pin tabs.
    4.  
    5. Drive the upper caliper pin inward until the tabs on the pin touch the spindle.
    6.  
    7. Insert a small prybar into the slot provided behind the pin tabs on the inboard side of the pin.
    8.  
    9. Using needlenosed pliers, compress the outboard end of the pin while, at the same time, prying with the prybar until the tabs slip into the groove in the spindle.
    10.  
    11. Place the end of a 7 / 16 inch; (11mm) punch against the end of the caliper pin and drive the pin out of the caliper slide groove.
    12.  
    13. Repeat this procedure for the lower pin.
    14.  
    15. Lift the caliper off of the rotor.
    16.  
    17. Remove the brake pads and anti-rattle spring.
    18.  

    Do not allow the caliper to hand by the brake hose.

    To install:
    1. Thoroughly clean the areas of the caliper and spindle assembly which contact each other during the sliding action of the caliper.
    2.  
    3. Place a new anti-rattle clip on the lower end of the inboard shoe. Make sure that the tabs on the clip are positioned correctly and the loop-type spring is away from the rotor.
    4.  
    5. Place the lower end of the inner brake pad in the spindle assembly pad abutment, against the anti-rattle clip, and slide the upper end of the pad into position. Be sure that the clip is still in position.
    6.  
    7. Check and make sure that the caliper piston is fully bottomed in the cylinder bore. Use a large C-clamp to bottom the piston, if necessary.
    8.  
    9. Position the outer brake pad on the caliper, and press the pad tabs into place with your fingers. If the pad cannot be pressed into place by hand, use a C-clamp. Be careful not to damage the lining with the clamp. Bend the tabs to prevent rattling.
    10.  
    11. Position the caliper on the spindle assembly. Lightly lubricate the caliper sliding grooves with caliper pin grease.
    12.  
    13. Position the a new upper pin with the retention tabs next to the spindle groove.
    14.  

    Don't use the bolt and nut with the new pin.

    1. Carefully drive the pin, at the outboard end, inward until the tabs contact the spindle face.
    2.  
    3. Repeat the procedure for the lower pin.
    4.  


    WARNING
    Don't drive the pins in too far, or it will be necessary to drive them back out until the tabs snap into place. The tabs on each end of the pin MUST be free to catch on the spindle sides!

    1. Install the wheels.
    2.  

    1976-83 with HD Sliding Caliper (Two Piston)

    See Figures 27, 28, 29 and 30

    1. To avoid overflowing of the master cylinder when the caliper pistons are pressed into the caliper cylinder bores, siphon or dip some brake fluid out of the larger reservoir.
    2.  
    3. Raise and support the front end on jackstands.
    4.  
    5. Jack up the front of the vehicle and remove the wheels.
    6.  



    Click image to see an enlarged view

    Fig. Fig. 27: Removing the key retaining screw



    Click image to see an enlarged view

    Fig. Fig. 28: Remove the spring and key.



    Click image to see an enlarged view

    Fig. Fig. 29: Bottoming the caliper pistons

    1. Remove the key retaining screw.
    2.  
    3. Using a brass drift and light hammer, drive out the caliper support key, and caliper support spring.
    4.  
    5. It is not necessary to disconnect the brake hose.
    6.  
    7. Remove the caliper from its support assembly by rotating the key and spring end out and away from the rotor. Slide the opposite end of the caliper clear of the slide in the support and off the rotor. Lay the tie rod on the tie rod or axle. Do not let the hang by the brake hose.
    8.  
    9. Remove the caliper brake shoe anti-rattle spring and the inner and outer shoe and lining assemblies.
    10.  
    11. Clean and inspect the caliper assembly. Thoroughly clean the area of the caliper and support that contact during the sliding action of the caliper.
    12.  
    13. Place a C-clamp on the caliper housing mid-way between between the piston bores, and using the inner shoe and lining over the pistons, tighten the C-clamp to bottom the caliper pistons in the cylinder bores. Remove the clamp and the inner shoe and lining assembly.
    14.  

    To install:
    1. Make sure the caliper pistons are fully bottomed in the cylinder bore.
    2.  
    3. Install the inner and outer shoe.
    4.  
    5. Position the caliper rail into the slide on the support and rotate the caliper onto the rotor.
    6.  
    7. Position the key and spring, and hand start the sub-assembly between the caliper and support. Note that the spring is between the key and caliper and that the spring tangs overlap the ends of the key. Use a suitable tool to hold up the caliper, if required, against the support assembly.
    8.  
    9. Using a hammer, drive the key and spring into position aligning the correct notch with the existing hole in the support.
    10.  



    Click image to see an enlarged view

    Fig. Fig. 30: Caliper spring and key

    1. Secure the the key to the support with the key retaining screw.
    2.  
    3. Install the wheels.
    4.  

    1984-86 with HD sliding Caliper (Two Piston)

    See Figures 31, 32, 33, 34 and 35

    1. To avoid overflowing of the master cylinder when the caliper pistons are pressed into the caliper cylinder bores, siphon or dip some brake fluid out of the larger reservoir.
    2.  
    3. Raise and support the front end on jackstands.
    4.  
    5. Jack up the front of the vehicle and remove the wheels.
    6.  



    Click image to see an enlarged view

    Fig. Fig. 31: Bottoming the caliper piston



    Click image to see an enlarged view

    Fig. Fig. 32: Compressor spring tabs

    1. Place an 8 inch; (203mm) on the caliper and tighten the clamp to bottom the caliper pistons in the cylinder bores. Remove the C-clamp.
    2.  
    3. Clean the excess dirt from around the caliper pin tabs.
    4.  
    5. Drive the upper caliper pin inward until the tabs on the pin touch the spindle.
    6.  
    7. Insert a small prybar into the slot provided behind the pin tabs on the inboard side of the pin.
    8.  
    9. Using needlenosed pliers, compress the outboard end of the pin while, at the same time, prying with the prybar until the tabs slip into the groove in the spindle.
    10.  
    11. Place the end of a 7 / 16 inch; (11mm) against the end of the caliper pin and drive the pin out of the caliper slide groove.
    12.  
    13. Repeat this procedure for the lower pin.
    14.  
    15. Lift the caliper off of the rotor.
    16.  
    17. Remove the brake pads and anti-rattle spring.
    18.  

    Do not allow the caliper to hand by the brake hose.

    To install:
    1. Thoroughly clean the areas of the caliper and spindle assembly which contact each other during the sliding action of the caliper.
    2.  
    3. Place a new anti-rattle clip on the lower end of the inboard shoe. Make sure that the tabs on the clip are positioned correctly and the loop-type spring is away from the rotor.
    4.  
    5. Place the lower end of the inner brake pad in the spindle assembly pad abutment, against the anti-rattle clip, and slide the upper end of the pad into position. Be sure that the clip is still in position.
    6.  
    7. Check and make sure that the caliper piston is fully bottomed in the cylinder bore. Use a large C-clamp to bottom the piston, if necessary.
    8.  
    9. Position the outer brake pad on the caliper, and press the pad tabs into place with your fingers. If the pad cannot be pressed into place by hand, use a C-clamp. Be careful not to damage the lining with the clamp. Bend the tabs to prevent rattling.
    10.  



    Click image to see an enlarged view

    Fig. Fig. 33: Correct caliper pin installation



    Click image to see an enlarged view

    Fig. Fig. 34: Disc brake assembly, 1984-86 F-250 (above 6900 GVWR) and F-350 (4x2)



    Click image to see an enlarged view

    Fig. Fig. 35: Disc brake assembly, 1984-86 F-250, 350 (4x4)

    1. Position the caliper on the spindle assembly. Lightly lubricate the caliper sliding grooves with caliper pin grease.
    2.  
    3. Position the a new upper pin with the retention tabs next to the spindle groove.
    4.  

    Don't use the bolt and nut with the new pin.

    1. Carefully drive the pin, at the outboard end, inward until the tabs contact the spindle face.
    2.  
    3. Repeat the procedure for the lower pin.
    4.  


    WARNING
    Don't drive the pins in too far, or it will be necessary to drive them back out until the tabs snap into place. The tabs on each end of the pin MUST be free to catch on the spindle sides!

    1. Install the wheels.
    2.  

     
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