Ford Pick-ups and Broncos 1987-1996 Repair Guide

Brake Disc (Rotor)



Except F-Super Duty with 4-Wheel Disc Brakes

See Figure 1

Click image to see an enlarged view

Fig. Fig. 1: Secure the caliper so there is no tension on the brake hose

  1. Jack up the front of the truck and support it with jackstands. Remove the front wheel.
  3. Remove the caliper assembly and support it on the frame with a piece of wire (or something equally secure) without disconnecting the brake fluid hose.
  5. Remove the hub and rotor assembly.
  7. Install the rotor in the reverse order of removal, and adjust the wheel bearing as outlined in Routine Maintenance .

F-Super Duty with 4-Wheel Disc Brakes

The hub and rotor are individual pieces, allowing the rotor to be replaced independently. The front and rear rotors are the same and are attached with 10 bolts and washers. The bolts are tightened a little at a time, in a crisscross fashion, to an ultimate torque of 74-89 ft. lbs. (100-121 Nm).


If the rotor is deeply scarred or has shallow cracks, it may be refinished on a disc brake rotor lathe. Also, if the lateral run-out exceeds 0.010 in. (0.25mm) within a 6 in. (152mm) radius when measured with a dial indicator, with the stylus 1 in. (25mm) in from the edge of the rotor, the rotor should be refinished or replaced.

A maximum of 0.020 in. (0.5mm) of material may be removed equally from each friction surface of the rotor. If the damage cannot be corrected when the rotor has been machined to the minimum thickness shown on the rotor, it should be replaced.

The finished braking surfaces of the rotor must be parallel within 0.007 in. (0.18mm) and lateral run-out must not be more than 0.003 in. (0.076mm) on the inboard surface in a 5 in. (127mm) radius.