Ford Pick-ups and Broncos 1987-1996 Repair Guide

Brake Pads



Never replace the pads on one side only! Always replace pads on both wheels as a set!

  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.
  3. Raise and support the rear end on jackstands.
  5. Remove the wheels.
  7. Place an 8 in. (203mm) C-clamp on the caliper and tighten the clamp to bottom the caliper pistons in the cylinder bores. Remove the C-clamp.
  9. Clean the excess dirt from around the caliper pin tabs.
  11. Drive the upper caliper pin inward until the tabs on the pin touch the caliper support.
  13. Insert a small prybar into the slot provided behind the pin tabs on the inboard side of the pin.
  15. Using needlenose 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 caliper support.
  17. Place the end of a 7 / 16 in. (11mm) punch against the end of the caliper pin and drive the pin out of the caliper slide groove.
  19. Repeat this procedure for the lower pin.
  21. Lift the caliper off of the rotor.
  23. Remove the brake pads and anti-rattle spring.

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

  1. Thoroughly clean the areas of the caliper and caliper support assembly which contact each other during the sliding action of the caliper.

To install:
  1. 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.
  3. Place the lower end of the inner brake pad in the caliper support 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.
  5. Check and make sure that the caliper pistons are fully bottomed in the cylinder bores. Use a large C-clamp to bottom the pistons, if necessary.
  7. 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.
  9. Position the caliper on the caliper support. Lightly lubricate the caliper sliding grooves with caliper pin grease.
  11. Position the a new upper pin with the retention tabs next to the support groove.

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 caliper support face.
  3. Repeat the procedure for the lower pin.

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 support sides!

  1. Install the wheels.


Remove the brake pads and measure the thickness of the lining. If the lining at any point on the pad assembly is less than 1 / 16 in. (0.8mm) 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.