REMOVAL & INSTALLATION
- Raise and safely support the vehicle securely on jackstands.
- Remove the front wheels.
- Remove the front brake hose bolt, then remove the copper washers and plug the front brake hose.
- Remove the 2 front disc brake caliper slide pins, then lift the caliper off of the front caliper anchor plate.
- Install the front disc brake caliper onto the caliper anchor plate, then install the 2 slide pins. Tighten the slider pins/bolts to 16-30 ft. lbs. (22-40 Nm) on the 1997-98 F-250HD, F-350 and F-Super Duty models. Tighten the bolts to 21-26 ft. lbs. (28-36 Nm) on the F-150, F-250, Expedition and Navigator. Tighten the bolts to 42 ft. lbs. (56 Nm). On the 1999-00 F-Super Duty models.
- Using new copper washers, attach the front brake hose to the brake caliper, then install and tighten the retaining bolt to 23-29 ft. lbs. (30-40 Nm).
- Bleed the brake system.
- Clean the wheel hub mounting surface.
- Install the front wheels and snug the lug nuts to fully seat the wheel against the hub.
- Lower the vehicle until some of the vehicle's weight rests on the front tires, then tighten the lug nuts to 83-112 ft. lbs. (113-153 Nm).
- Lower the vehicle completely.
- Make sure that the brakes are operating correctly.
1997-98 F-SUPER DUTY
- Remove sufficient brake fluid from the brake master cylinder reservoir to allow for pressing the caliper pistons into the bores. Discard the used brake fluid.
- Raise and safely support the vehicle.
- Remove the wheels.
- Place a suitable C-clamp on the caliper, with he clamp frame on the disc brake caliper and the clamp screw on the outboard brake hoes and lining backing plate, then tighten the clamp to press the caliper pistons in the cylinder bores only enough to give removal clearance. Remove the C-clamp.
- Remove the rear brake hose-to-caliper flow bolt and discard the used copper washers. Plug the brake hose so that contamination of the brake fluid does not occur.
- Using the Caliper Pin Remover D89T-2196-A, or equivalent, drive the upper and lower caliper locking pins out.
- Remove the disc brake caliper from the vehicle.
- If necessary, install the brake shoe 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 or equivalent.
- Drive the 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 22-29 ft. lbs. (30-39 Nm).
- Install the wheel, then lower the vehicle.
Check the brake fluid level in the brake master cylinder reservoir and maintain sufficient level to prevent air from entering the system.
- Pump the brake pedal several times to drive the caliper pistons into contact with the brake shoe and lining.
- Fill the brake master cylinder reservoir with new DOT 3 brake fluid.
- Bleed the brake system and test the brakes for proper operation.
- Raise and support the vehicle.
- Remove the wheel and tire assembly.
- Remove bolt and disconnect the rear wheel brake hose.
- Remove the copper washers and plug the brake hose.
- Remove the brake caliper bolts.
- Lift the rear disc brake caliper off the rear disc brake caliper anchor plate.
- Inspect the rear disc brake caliper for leaks.
When installed, the locator notch on the brake pads will be located at the upper end of the rear disc brake caliper.
- Install the rear disc brake caliper.
- Install the rear wheel brake hose.
- Connect the brake hose and install and use new copper washers.
- Tighten the brake hose bolt.
- Bleed the disc brake caliper.
If equipped with air suspension, reactivate the system by turning on the air suspension switch.
- Install the wheel and tire assembly.
- Verify correct brake operation.
Some vehicles may be equipped dual piston calipers. The procedure to overhaul the caliper is essentially the same with the exception of multiple pistons, O-rings and dust boots.
- Remove the caliper from the vehicle and place on a clean workbench.
Depending upon the vehicle, there are two different ways to remove the piston from the caliper. Refer to the brake pad replacement procedure to make sure you have the correct procedure for your vehicle.
The first method is as follows:
- Stuff a shop towel or a block of wood into the caliper to catch the piston.
- Remove the caliper piston using compressed air applied into the caliper inlet hole. Inspect the piston for scoring, nicks, corrosion and/or worn or damaged chrome plating. The piston must be replaced if any of these conditions are found.
- For the second method, you must rotate the piston to retract it from the caliper.
- If equipped, remove the anti-rattle clip.
- Use a prytool to remove the caliper boot, being careful not to scratch the housing bore.
- Remove the piston seals from the groove in the caliper bore.
- Carefully loosen the brake bleeder valve cap and valve from the caliper housing.
- Inspect the caliper bores, pistons and mounting threads for scoring or excessive wear.
- Use crocus cloth to polish out light corrosion from the piston and bore.
- Clean all parts with denatured alcohol and dry with compressed air.
- Lubricate and install the bleeder valve and cap.
- Install the new seals into the caliper bore grooves, making sure they are not twisted.
- Lubricate the piston bore.
- Install the pistons and boots into the bores of the calipers and push to the bottom of the bores.
- Use a suitable driving tool to seat the boots in the housing.
- Install the caliper in the vehicle.
- Install the wheel and tire assembly, then carefully lower the vehicle.
- Properly bleed the brake system.