Disc & Drum Ford Econoline E350

DESCRIPTION & OPERATION

Note. Unless otherwise specified, references to Pickup include the F350 Super Duty commercial chassis.

Note. For any problems with abbreviations please see the ABBREVIATIONS article in the GENERAL INFORMATION Section.

MODEL IDENTIFICATION

Front disc and rear drum brakes are standard on all models except "F" Series Super Duty, which comes with front and rear disc brakes. A single anchor, dual piston brake assembly is used on E250/350, F250/350 and front and rear on "F" Series Super Duty. All other models use a single piston, pin rail sliding caliper front disc brake system. Rear drum brake assembly consists of a support plate, 2 brake shoes, return springs, automatic adjuster components and one dual piston wheel cylinder. On Aerostar, Explorer and Ranger, brake drums are available in 9" and 10" sizes.

On rear drum brake models, parking brake is actuated by a cable, which pulls the parking brake lever located inside rear brake assembly. The lever pivots parking brake strut between brake shoes. This movement pushes outward on brake shoes. The brake shoe linings are made of asbestos-free fiberglass material.

"F" Series Super Duty, equipped with rear disc brakes, uses a cable actuated, transmission mounted parking brake. Transmission mounted parking brake is situated on transmission extension housing, and consists of a case assembly and cable actuated 9" x 3" Bendix brake assembly. (Scheme 1) Case assembly consists of roller bearings, companion flange and mainshaft, assembled in a one-piece aluminum housing. Case assembly has a lubrication supply separate from transmission.

Note. All Figures in this article are Courtesy of Ford Motor Co.

Scheme 1

Aerostar is equipped with a cartridge master cylinder and vacuum booster. The cartridge-type master cylinder has, in addition to the standard primary and secondary pistons, a by-pass proportioning valve and differential pressure switch.

Bronco, Explorer, Ranger and "E" & "F" Series models are equipped with dual master cylinder and vacuum booster. The dual master cylinder has primary and secondary pistons and separate primary and secondary fluid reservoirs. "F" Series Super Duty model uses a dual master cylinder and hydro-boost. On all models, caliper is secured to steering knuckle by 2 caliper retaining pins. Aerostar, Explorer and Ranger use a dual-diaphragm vacuum booster; all others use single or dual-diaphragm vacuum booster.

The single and dual-diaphragm (tandem) vacuum boosters are self-contained, vacuum power brake units. The booster assists in actuating master cylinder push rod. Booster contains either a single or dual vacuum-suspended diaphragm which uses engine manifold vacuum or atmospheric pressure for power. Diesel powered vehicles use a belt-driven vacuum pump to provide vacuum for booster actuation.

A mechanically operated booster check valve controls power brake application and release in relation to foot pressure applied to check valve operating rod. Booster check valve is the only serviceable component of brake booster assembly. The "F" Series Super Duty hydro-boost is hydraulically operated by the power steering pump and provides a variable power assist regulated by brake pedal pressure.

Hydro-boost has a reserve system (compressed gas accumulator) which stores enough fluid under pressure to provide at least 2 power-assisted brake applications if power steering pump fluid flow stops. Brakes can also be operated manually if reserve system is lost.

Hydro-boost power units in normal condition produce certain noises. These noises occur when brakes are used more than usual. In general, these noises are hissing, clunks, clicks and chattering. Hydro-boost hisses when greater than normal braking effort is used. Hissing increases when pedal effort and operating temperatures increase. Loud hissing at normal pedal effort of 25-35 lbs. (11-16 kg.) or less should be investigated. Clunk, chatter and clicking noises are heard when brake pedal is quickly released from hard braking.

A fluid level indicator is located in the plastic reservoir of each master cylinder. It is not serviced separately. It consists of a float, magnet assembly and reed switch. The magnet operates the reed switch when fluid is low and activates a dash-mounted warning light.

The cartridge-type master cylinder on Aerostar uses a pressure differential warning switch. This switch lights brake warning light on dash if pressure in either front or rear brake system becomes too low.

Aerostar and some Bronco and "E" & "F" Series vehicles use a proportioning valve integral with master cylinder. (Scheme 2) This proportioning valve has a by-pass feature. The proportioning valve restricts hydraulic pressure to the rear brakes to prevent lock-up. The by-pass feature allows full hydraulic pressure to the rear brakes in case of front brake system failure.

Examining Master Cylinder & Proportioning Valve (Bronco, "E" & "F" Series). Scheme 2

"F" Series Super Duty vehicles are equipped with a height sensing proportioning valve. (Scheme 3) The height sensing proportioning valve monitors changes in vehicle height. This valve automatically provides optimum front-to-rear brake balance, regardless of vehicle load. The valve controls pressure to rear brakes by sensing vehicle load conditions through movement between rear axle and body. As vehicle load increases (resulting in decreased vehicle height), higher brake line pressure to rear brakes is allowed. The valve is located on No. 5 crossmember.

Examining Height Sensing Proportioning Valve ("F" Series Super Duty). Scheme 3

BLEEDING BRAKE SYSTEM

Bleed hydraulic system whenever air has been introduced into system. Bleed master cylinder and brakes at all 4 wheels if master cylinder lines have been disconnected or master cylinder has run dry. Bleed brakes with pressure bleeding equipment or by manually pumping brake pedal while using bleeder tubes. Always bleed brake lines in sequence. See BLEEDING SEQUENCE .

Note. Do not allow reservoir to run dry during bleeding operation.

MANUAL BLEEDING

Note. Manual bleeding procedures for Bronco and "E" & "F" Series vehicles are not available from manufacturer, but should be similar to other manual bleeding procedures.

Scheme 4

1. Clean master cylinder cap and surrounding area. Remove cap. Explorer and Ranger models are equipped with dual-type master cylinder. Aerostar has a cartridge-type master cylinder. On Explorer and Ranger, bleed primary and secondary systems separately. On Explorer and Ranger, loosen primary or secondary master cylinder hydraulic line fitting. (Scheme 4)
2. On Aerostar, loosen either master cylinder hydraulic line. On all models, wrap a cloth around brake lines to absorb escaping brake fluid (on Aerostar, bleed longest line first). Slowly push brake pedal down to force out air. With pedal fully depressed, tighten fittings to prevent air from being sucked into master cylinder when pedal is released. Release pedal.
3. Repeat procedure until air is completely purged from master cylinder. When all air has escaped, tighten fittings with pedal down. Release pedal, and depress again. If pedal is not firm, repeat bleeding procedure.
4. On Aerostar, attach a rubber drain hose to bleeder fitting on front of master cylinder. Submerge hose in small container half-filled with clean brake fluid. Open bleeder fitting. Loosen bleeder fitting about3/4 turn. Slowly push down brake pedal completely.
5. Close bleeder fitting, and return pedal to fully released position. Repeat procedure until all air is purged from master cylinder. On all models, repeat procedure at bleeder fitting on Rear Anti-Lock Brake Electro-Hydraulic Valve and each wheel cylinder. See «BLEEDING SEQUENCE»(/ford/econoline-e350/1985-1999/remont/mechanical-hydraulic/#disc-drum) under BLEEDING SEQUENCE. (Scheme 5) When bleeding is complete, fill master cylinder to proper level.

Scheme 5

PRESSURE BLEEDING

1. Clean master cylinder cap and surrounding area. Remove cap. With pressure tank at least 1/2 full of specified fluid and charged between 10-30 psi (.7-2.0 kg/cm 2 ), use adapters to connect tank to master cylinder. Follow equipment manufacturer's pressure instructions. CAUTION: NEVER exceed 50 psi (3.5 kg/cm 2 ) during bleeding.
2. Open pressure bleeder valve. On Aerostar, attach one end of rubber drain tube to master cylinder bleeder fitting. Open bleed fitting. On all others, bleed master cylinder primary and secondary hydraulic lines individually. Put shop towels in place to catch brake fluid.
3. Open lines. On all models, allow brake fluid to flow out until all air is purged. Close bleed fitting and hydraulic line. Close pressure bleeder valve. Attach rubber drain hose to first wheel cylinder bleeder valve to be serviced. (Scheme 5) Refer to «BLEEDING SEQUENCE»(/ford/econoline-e350/1985-1999/remont/mechanical-hydraulic/#disc-drum) under BLEEDING SEQUENCE.
4. Place other end of hose in clean glass jar partially filled with clean brake fluid so end of hose is submerged in fluid. Open pressure bleeder valve. Open bleeder fitting. Close bleeder fitting when fluid flow is free of bubbles. Repeat procedure on remaining wheel cylinders in sequence. See «BLEEDING SEQUENCE»(/ford/econoline-e350/1985-1999/remont/mechanical-hydraulic/#disc-drum).
5. When bleeding operation is complete, close pressure bleeder valve, and remove tank hose from adapter fitting. Check brake pedal operation. Ensure master cylinder is full of fluid.

BLEEDING SEQUENCE

Before bleeding system, remove all vacuum from power unit by depressing brake pedal several times. Bleed master cylinder first, followed in sequence by rear wheel cylinders, anti-lock system components (if equipped) and calipers. See BLEEDING SEQUENCE .

BLEEDING SEQUENCE

"F" Series Super Duty

1. Fill power steering pump reservoir with Motorcraft MERCON multipurpose automatic transmission fluid. Crank engine several seconds with coil wire disconnected. Check and add fluid if necessary. Start engine. Turn wheels from lock-to-lock twice.
2. Turn engine off. Depress brake pedal several times to discharge accumulator. Start engine, and turn wheels from lock-to-lock twice. If foaming occurs, stop engine, and allow foam to dissipate. Repeat lock-to-lock procedure until all air is removed from system.

Note. Hydro-boost is generally self-bleeding. Listed procedure will normally bleed air from system. Normal vehicle operation will remove any additional air.

VACUUM POWER BOOSTER PUSH ROD

Note. Brake booster push rod on Aerostar should not be readjusted.

1. Push rod has an adjustment screw to maintain correct distance between booster push rod and master cylinder piston. If push rod is adjusted too long, it prevents master cylinder piston from completely releasing hydraulic pressure, causing brakes to drag. If push rod is adjusted too short, it causes excessive pedal travel and an undesirable clunk in booster area.
2. Remove master cylinder to gain access to push rod. To check screw adjustment, fabricate a gauge. (Scheme 6)
3. Place gauge against master cylinder mounting surface of booster. Adjust push rod screw by turning it until end of screw just touches inner edge of gauge slot.

Adjusting Brake Booster Push Rod (All Models Except Aerostar & "F" Series Super Duty). Scheme 6

Remove spring clip and washer from lower end of brake pedal rod. Remove lower end of rod from bellcrank pin. Loosen jam nut. Hold brake pedal against rubber stop. Turn brake rod into clevis until lower hole lines up with pin on bellcrank. Slide brake rod onto pin of bellcrank, and attach washer and spring clip. (Scheme 7)

Scheme 7

Scheme 8

1. Raise rear of vehicle using body jacks to gain a clearance of 6 5/8" (168 mm) between bottom surface of each rubber jounce bumper and rear axle housing. (Scheme 8) Remove nut from valve shaft, and remove leading arm. (Scheme 8): Adjusting Height Sensing Proportioning Valve ("F" Series Super Duty)
2. Remove bushing and clip from leading arm. Install new bushing and clip from linkage kit (E8TZ-2L 193-A). Rotate valve shaft one full turn in either direction. Position valve shaft with flat at bottom and parallel with ground. (Scheme 8)
3. Install Indexing Plate (T90T-2588-A) on valve shaft. Install so flat on indexing plate is aligned with flat on valve shaft. Indexing plate slot must be fully seated on valve shaft. Upper surface of indexing plate must rest on valve body.
4. Rotate indexing plate counterclockwise until edge of indexing plate touches brake hose block. (Scheme 8) While holding indexing plate in position, install leading arm of linkage over splined part of valve shaft. Fully seat leading arm onto splines. Reinstall valve shaft nut. Remove indexing plate.

PARKING BRAKE

Note. Aerostar parking brake system is self-adjusting and requires no adjustment. On all other models except "F" Series Super Duty, initial adjustment procedure must be performed if tension limiter is replaced. If tensioner limiter has not been replaced, use field adjustment to remove cable slack.

Field Adjustment (Explorer & Ranger)

1. Adjust service brakes before adjusting parking brake cable. Ensure brake drums are cold. Apply parking brake to fully depressed position. Grip threaded rod to prevent it from spinning.
2. Thread equalizer nut 6 full turns past its original position on threaded rod. Check cable tension at rear of equalizer assembly using Cable Tension Gauge (021-00018). If tension is not 400-600 lbs.(182-272 kg), repeat step 2).
3. Release pedal, and check rear wheel drag. If drag is noted, remove drums, and check for clearance between parking brake lever and cam plate. Cables should be tight enough to allow full application of rear brakes and loose enough to allow full release of rear brakes.

Note. Tension limiter will reset parking brake tension any time system is disconnected if distance between bracket and cinch strap hook is reduced during adjustment. When adjustment has been performed so cinch strap contacts bracket, system tension will increase greatly. This may cause an over-tension condition. When available adjustment travel has been used, replace tension limiter.

Note. If rear brake shoes are removed for any reason, parking brake cable tension should be checked and adjusted.

Initial Adjustment (Bronco, "E" & "F" Series)

1. Adjust rear brakes before adjusting parking brake cables. Press parking brake lever to last detent position. On models with hand-operated (Orschein) parking brake, turn handle adjustment knob clockwise to end of travel. Apply parking brake. On all models, grip tension limiter housing to prevent it from spinning.
2. On Bronco and F150/350, thread equalizer nut 2.78-3.02"(70.6-76.7 mm) up rod. On E150/350, thread equalizer nut 2.98-3.22" (75.7-81.8 mm) up rod. Ensure cinch strap has slipped so less than 1.50" (38.1 mm) remains exposed. (Scheme 9)
3. On models with Orschein parking brake, release parking brake. Turn handle adjustment knob counterclockwise to obtain a minimum tension of 350 lbs. (159 kg) on Cable Tension Gauge (021-00018) with parking brake fully applied.

Adjusting Parking Brake (Except Aerostar & "F" Series Super Duty). Scheme 9

Field Adjustment (Bronco, "E" & "F" Series)

1. Adjust rear brakes before adjusting parking brake cables. Use this procedure to correct slack in cable. Ensure brake drums are cold. Press parking brake to fully applied position. On models with Orschein parking brake, apply parking brake. On all models, grip tension limiter housing to prevent it from spinning.
2. Thread equalizer nut 6 turns past original position until cinch strap begins to slip. Check cable tension at rear of equalizer assembly using Cable Tension Gauge (021-00018). Tension should be at least 310 lbs. (140 kg) on models with Orschein parking brake and 350 lbs. (159 kg) on all others. If tension is below specifications, adjust equalizer nut again.
3. Release parking brake pedal or parking brake handle, and check for rear wheel drag. If drag is noted, remove drums, and check for clearance between parking brake lever and cam plate. Clearance should be .015" (.38 mm) with parking brake fully released. If clearance is incorrect, readjust parking brake cable.

Note. Tension limiter will reset parking brake tension any time system is disconnected if distance between bracket and cinch strap hook is reduced during adjustment. When adjustment has been performed so cinch strap contacts bracket, system tension will increase greatly. This may cause an over-tension condition. When available adjustment travel has been used, replace tension limiter.

Field Adjustment For Tight System (Bronco, "E" & "F" Series)

1. Ensure brake drums are cold. Press parking brake pedal to floor. Release parking brake. Apply and release once again. Pressing park brake pedal to floor causes tension limiter to automatically set cable tension and pedal feel.
2. Release parking brake lever. Install Cable Tension Gauge(021-00018) on cable, 2 1/2" behind equalizer. Apply parking brake. Cable tension should be a minimum of 350 lbs. (159 kg). If tension is below specification, repeat procedure.

Transmission Mounted Parking Brake Field Adjustment ("F" Series Super Duty)

1. Use this procedure to correct excess parking brake actuation lever travel. On foot actuated lever, raise vehicle and set on jack stands. Shift transmission to Neutral, and release parking brake. Loosen parking brake clevis adjusting jam nut several turns.
2. Remove lock pin and clevis pin from clevis. (Scheme 10) Hold lever and cable, removing slack. Screw adjusting clevis onto threaded end of cable until parking brake lever hole and clevis hole meet. Rotate clevis about 10 turns. Tighten jam nut. Rotate driveshaft to ensure rear brakes are not dragging. Lower vehicle to ground. Check parking brake for proper operation.
3. On vehicles with Orschein hand-actuated parking brake lever, turn handle adjustment knob to obtain one inch of travel. (Scheme 10) Release parking brake. Loosen parking brake clevis adjusting jam nut several times. Install parking brake cable into parking brake mounting bracket.
4. Hold parking brake actuation lever in applied position. Screw adjusting clevis onto threaded end of cable until parking brake lever hole and clevis hole meet. Rotate clevis about 10 turns. Tighten jam nut. Assemble clevis to parking brake actuation lever. Check parking brake for proper operation. Turn adjustment knob on parking brake actuation lever for additional adjustment.

Scheme 10

BRAKE SHOES

Note. Rear brake shoes are automatically adjusted when vehicle is driven forward and backward and brakes are applied sharply. Manual adjustment is required if brakes do not self-adjust or after brake shoes have been removed or replaced.

Scheme 11

1. Adjust with brake drums cold and parking brake correctly adjusted. Measure brake drum inside diameter using brake shoe adjustment gauge. (Scheme 11)
2. Reverse adjustment gauge. Apply gauge to brake shoes on a line parallel to ground and through center of axle. Hold adjusting lever away from adjusting screw. Turn screw until outside diameter of shoes contacts gauge. (Scheme 11)
3. Install brake drum and wheel assembly. Complete adjustment by applying brakes quickly several times while driving vehicle alternately forward and backward. Check brake operation by stopping often while driving forward.

Drums Installed

1. Raise vehicle, and support with safety stands. Remove adjusting hole cover rubber plug. Turn adjusting screw and expand brake shoes until drag is felt against brake drum.
2. Loosen adjusting screw 10-12 notches. Drum should rotate freely without drag. If drum does not rotate freely, remove wheel and drum. Lubricate brake shoe contact areas on backing plate.
3. Reinstall wheel and drum. Install adjusting hole cover. Apply brakes. If brake pedal travels more than halfway to floor, clearance between brake shoes and drums is too great. Additional adjustment is required.

DISC PADS

As brake pads wear, caliper piston remains in constant contact with brake pad, eliminating need for adjustment.

MASTER CYLINDER

Changes in brake pedal feel or travel signal something could be wrong in brake system. When diagnosing brake system problems, use brake warning light, pedal feel/travel and fluid level as indicators. Following symptoms indicate brake trouble

Pedal goes down fast.

1. This could be caused by leaks or air in system.

Pedal goes down slowly.

1. This could be caused by external or internal leaks.

Pedal is low and/or feels spongy.

1. This may be caused by empty master cylinder reservoir, reservoir cap vent holes clogged, rear brakes out of adjustment or air in system.

Pedal effort too high.

1. Check for binding or obstruction in pedal linkage. Check for poor booster assist.

Brake warning light is on.

1. Check for low fluid level, ignition wires too close to fluid level indicator assembly, damaged indicator float, low vacuum (diesel) or applied parking brake.

HYDRO-BOOST UNIT

Use following list of symptoms to aid in diagnosing hydro-boost problems

Brake pedal returns slowly.

1. Check for restriction in return line between hydro-boost and power steering reservoir.
2. Check for incorrectly connected return line.
3. Reposition brake pedal or add return spring.
4. Replace hydro-boost.

Brakes grab.

1. Tighten power steering belt.
2. Flush steering system while pumping brake pedal.
3. Replace hydro-boost.

Hydro-boost chatter/Pedal vibration.

1. Tighten power steering belt.
2. Check for low fluid level.

Accumulator leaks down/No reserve brake application.

1. Replace hydro-boost.

High brake pedal effort.

1. Tighten or replace power steering belt.
2. Low fluid level.
3. Replace hydro-boost.

Brakes apply by themselves.

1. Restriction in return line.
2. Return line not connected correctly.
3. Replace hydro-boost.

POWER BRAKE FUNCTION TEST

1. With engine stopped, remove all vacuum in system by pumping brake pedal several times. Push pedal down as far as it will go. If pedal moves downward slowly, hydraulic system is leaking. Check hydraulic system for leaks.
2. With pedal pushed down as far as it will go, start engine. If pedal moves downward, vacuum system is okay. If pedal does not change position, a problem exists in vacuum system. Check vacuum system for leaks.

Bronco, "E" & "F" Series

1. To check master cylinder for internal leak, fill reservoir as necessary. If fluid level remains constant after several brake applications, measure wheel turning torque necessary to rotate wheels with brakes applied.
2. To measure, shift transmission into Neutral, and raise front wheels. Apply brakes with a minimum force of 100 lbs. (45 kg), and hold about 15 seconds. With brakes applied, attempt to rotate front wheels with 75 ft. lbs. (102 N.m) of torque. If either wheel rotates, check front chamber of master cylinder, and replace parts as necessary. Repeat test for rear wheels.

BRAKE WARNING LIGHT

1. Brake warning light should only come on when ignition is in start position or when ignition is on with parking brake applied or fluid level low. On diesel vehicles, brake warning light should also come on when vacuum is low.
2. If brake warning light does not come on when brake fluid is low, manually push reservoir float to bottom of reservoir. If light still does not come on, check circuit fuse, wiring and bulb. Repair as necessary. If bulb and related circuitry are okay, replace reservoir assembly.
3. If brake warning light does not come on when parking brake is applied, check parking brake switch, circuit wiring and bulb. Repair as necessary. With parking brake released and master cylinder reservoir full, turn ignition on. If warning light is on, check for shorted, grounded or defective warning switches or wiring. Repair as necessary. Turn ignition to start position. If brake warning light does not come on as a bulb check function, check fuse, bulb and wiring. Repair as necessary.

BRAKE PEDAL RESERVE

1. If complaint is low or bottoming out brake pedal, run engine at idle with transmission in Park or Neutral. Lightly depress brake pedal 3 or 4 times. Wait 15 seconds for vacuum to build in booster. Depress brake pedal until it stops moving downward.
2. While holding pedal down, raise engine speed to about 2000 RPM. Release accelerator pedal. Brake pedal should move downward as engine speed returns to idle. If results are correct, system has proper pedal reserve. If results are not correct, check for adequate vacuum. If vacuum is okay, replace vacuum booster.

HYDRO-BOOST RESERVE

Charge system with pressure by holding steering wheel on steering stop or by holding brake pedal down with 100 lbs. (45 kg) of force for 5 seconds with engine idling. Turn engine off. After 8-12 hours, depress brake pedal with engine off. If power reserve is not present, replace hydro-boost unit.

VACUUM POWER BOOSTER

1. With a "T" fitting, connect vacuum gauge into vacuum line between engine and power brake booster. With engine at operating temperature, gauge should read 15-19 in. Hg (51-64 kPa) at idle with transmission in Neutral. If reading is below specifications, stop engine, disconnect vacuum hose at power brake booster and cap open end of hose and open port of vacuum "T".
2. Start engine, and allow it to idle. If vacuum reading is still less than 15-19 in. Hg (51-64 kPa), engine is producing low vacuum and problem must be corrected. If vacuum is to specification, check plastic check valve, rubber grommet and vacuum hose connection at power brake booster.
3. With low engine vacuum corrected and/or leaking components replaced, start engine, and allow it to idle. Stop engine, and depress brake pedal, holding down a few seconds. If vacuum drops to zero, booster is leaking and requires replacement.

Removal (All But E250/350)

1. To prevent master cylinder overflow when caliper piston is depressed, remove and discard some brake fluid from master cylinder. Raise vehicle, and support with safety stands.
2. Remove front wheel assembly. Place a large "C" clamp on caliper. Tighten clamp to bottom piston in cylinder bore. Remove clamp.
3. Remove dirt around caliper pin tabs. Tap upper caliper pin toward inboard side of vehicle until pin tabs touch spindle face.
4. Insert screwdriver into slot provided behind pin tabs on inboard side of pin. Using pliers, compress end of pin while using screwdriver to pry until tabs slip into spindle groove.
5. Place a 7/16" diameter punch on end of pin, and drive caliper pin out of caliper slide groove. Repeat procedure for lower pin. Remove caliper from rotor. Remove outer brake pad. Compress anti-rattle spring clip, and remove inner brake pad. Support caliper aside.
6. On Aerostar, Explorer and Ranger, replace pads if lining is less than .12" (3.0 mm) thick at any point. On Bronco, E150 and F150, replace pads if lining is less than .06" (1.5 mm) above backing plate at any point. On E250/350, F250/350 and "F" Series Super Duty, replace pads if lining is less than .03" (.8 mm) above backing plate at any point.

Installation

Use "C" clamp to push caliper piston into piston bore until it bottoms out. To install, reverse removal procedure. Bleed air from brake system.

Removal (E250/350)

1. To prevent master cylinder overflow when caliper piston is depressed, remove and discard some brake fluid from master cylinder. Raise vehicle, and support with safety stands.
2. Remove front wheel assembly. Place a large "C" clamp on caliper. Tighten clamp to bottom piston in cylinder bore. Remove clamp. CAUTION: DO NOT use a screwdriver or similar tool to pry piston away from rotor.
3. Remove upper anchor bolt only. NOTE: The caliper does not have to be completely removed to remove and install brake shoe assemblies.
4. Swing caliper down. Remove brake shoe assemblies from spindle. To remove caliper first disconnect brake line from caliper.
5. Plug end of line to prevent fluid loss and entry of air into system. Remove lower anchor bolt and remove caliper.
6. Inspect slide pin assemblies from any damage or wear. Replace if necessary. Inspect rubber boots over anchor bolts. Replace if torn or deteriorated.

1. Install slide pin assemblies. Lubricate slides with Disc Brake Caliper Slide Grease D7AZ-19590-A (ESA-M1C172-A) or equivalent. Position shoes onto spindle.
2. Rotate caliper back up into position. Position caliper to spindle.
3. Install anchor bolt(s) through caliper and spindle. Tighten bolts to 85-100 ft.lbs. (115-135 N.m). Replace bolt washers (each side of inlet block). Reconnect fluid line. Tighten inlet block bolt to 10-15 ft.lbs. (13.6-20.3 N.m). Bleed system.
4. Install wheel and tire assemblies. Remove safety stands and lower vehicle. If brakes were not bled, check fluid level in master cylinder reservoir and fill if required. Pump brake several times to make sure you get a firm pedal. Operate vehicle to check brake operation.

Scheme 12

1. Remove wheel assembly and drum. Place a wheel cylinder clamp over ends of wheel cylinder. Disengage adjusting lever from adjusting screw by pulling backwards on lever cable. (Scheme 12)
2. Move outboard side of adjusting screw upward, and back off pivot nut as far as possible. Pull adjusting lever, cable and adjusting spring down and toward rear to unhook pivot hook from large hole in secondary shoe. DO NOT pry pivot hook from hole.
3. Remove adjusting spring and adjusting lever. Remove secondary shoe-to-anchor spring. Remove primary shoe-to-anchor spring. Unhook cable anchor, and remove anchor pin plate.
4. Remove cable guide, shoe hold-down springs, brake shoes, adjusting screw, pivot nut and socket. Remove parking brake link spring and link. Note color and position of springs for reassembly.
5. Disconnect parking brake cable from lever. Remove secondary shoe. Disassemble parking brake lever from shoe by removing retaining clip and spring washer.

Clean and sand brake shoe contact points on backing plate. Apply a light coating of lithium base grease to contact points. Lubricate adjusting cable eye and anchor pin area. Lubricate adjusting screw, pivot and socket. To install, reverse removal procedure.

Removal (E250/350 & F250/350)

1. Remove wheel assembly and brake drum. Remove parking brake lever assembly retaining nut from backing plate. Remove parking brake lever assembly. (Scheme 13) Remove adjusting cable assembly from anchor pin, cable guide and adjusting lever.
2. Remove brake shoe return springs, hold-down springs and brake shoes. Remove and disassemble adjusting screw assembly.

Scheme 13

Clean and sand brake shoe contact points on backing plate. Apply a light coating of lithium base grease to contact points. Lubricate adjusting cable eye and anchor pin area. Lubricate adjusting screw, pivot and socket. To install, reverse removal procedure.

Removal & Installation (2WD Models)

1. Raise vehicle, and support with safety stands. Remove wheel and caliper assemblies. Remove dust cap, cotter pin, nut, washer and outer bearing. Carefully remove hub and rotor assembly. Remove inner bearing and seal.
2. To install, reverse removal procedure. Adjust front wheel bearings. While rotating rotor, tighten adjusting nut to 17-25 ft. lbs. (23-34 N.m). Back off adjusting nut 120-180 degrees. Install bearing retainer and new cotter pin.

Removal & Installation (Aerostar 4WD)

Raise vehicle, and support with safety stands. Remove wheel and caliper assemblies. See DISC BRAKE CALIPERS & PADS under REMOVAL & INSTALLATION. Remove rotor retainer clips. Remove rotor. To install, reverse removal procedure.

Note. Information for rotor removal on vehicles with Dana 28 Series front axle is not available from manufacturer.

Removal (Explorer & Ranger 4WD W/Automatic Locking Hubs)

1. Raise vehicle, and support with safety stands. Remove wheel assembly and caliper. See «DISC BRAKE CALIPERS & PADS»(/ford/econoline-e350/1985-1999/remont/mechanical-hydraulic/#disc-drum) under REMOVAL & INSTALLATION. Remove retainer washers from lug nut studs. Remove automatic locking hub housing from spindle.
2. Remove snap ring from end of spindle shaft. Remove axle spacer. (Scheme 14) Carefully pull plastic moving cam off wheel bearing adjusting nut. Remove 2 plastic thrust spacers from adjusting nut. Using a magnet, remove locking key. CAUTION: DO NOT pry on plastic cam or spacers during removal as damage may result. To prevent damaging spindle threads, remove locking key before removing adjusting nut.
3. If necessary, rotate adjusting nut slightly to relieve pressure on locking key. Using Hex Lock Nut Wrench (T70T-4252-B), remove wheel bearing adjusting nut. Remove outer wheel bearing, and then remove rotor.

Removing Front Rotor (4WD Explorer & Ranger W/Automatic Locking Hubs). Scheme 14

When installing rotor, outer bearing and adjusting nut, tighten adjusting nut to 35 ft. lbs (47 N.m) to seat bearings. Spin rotor, and back off adjusting nut 1/4 turn. Tighten adjusting nut to 16 INCH lbs. (1.8 N.m). To install remaining components, reverse removal procedure. (Scheme 14) After assembly is complete, wheel to spindle end play should be.001-.003" (.02-.08 mm).

Removal (Explorer & Ranger 4WD W/Manual Locking Hubs)

1. Raise vehicle, and support with safety stands. Remove wheel assembly and caliper. See «DISC BRAKE CALIPERS & PADS»(/ford/econoline-e350/1985-1999/remont/mechanical-hydraulic/#disc-drum) under REMOVAL & INSTALLATION. Remove retainer washers from lug nut studs. Remove manual locking hub housing from spindle.
2. Remove snap ring from end of spindle shaft. Remove axle spacer. (Scheme 15) Using Lock Nut Wrench (T86T-1197-A), remove outer wheel bearing lock-nut. Remove lock washer. Using Lock Nut Wrench (T86T-1197-A), remove inner wheel bearing lock nut, outer wheel bearing and rotor.

Removing Front Rotor (4WD Explorer & Ranger W/Manual Locking Hubs). Scheme 15

When installing rotor, outer bearing and inner lock nut, tighten inner lock nut to 35 ft. lbs (47 N.m) to seat bearings. Spin rotor, and back off inner lock nut 1/4 turn. Tighten inner lock nut to 16 INCH lbs. (1.8 N.m). To install remaining components, reverse removal procedure. (Scheme 15) After assembly is complete, wheel to spindle end play should be.001-.003" (.02-.08 mm).

Scheme 16

1. Raise vehicle, and support with safety stands. Remove wheel assembly and caliper. On Bronco and F150 Series with automatic locking hubs, separate hub cap from hub body assembly by removing 5 Torx (TX25) head cap screws. (Scheme 16) Remove cap. DO NOT drop spring, ball bearing, bearing race or retainer. NOTE: Information for rotor removal on F250/F350 with automatic locking hubs is not available from manufacturer. Procedure should be similar to other locking hub procedures.
2. Remove rubber seal and seal bridge from retainer ring space. Remove retainer ring by squeezing ends together. Remove hub body assembly. Remove "C" washer and splined spacer from spindle. On Bronco and "F" Series with manual locking hubs, separate hub cap from hub body assembly by removing 6 Allen head screws.
3. Remove snap ring attaching hub body assembly to spindle. Remove lock ring seated in groove of hub. (Scheme 17) Remove hub body assembly. If hub body does not come out easily, install 2 hub cap screws into hub body, and pull hub body out of hub.
4. On Bronco and F150 with automatic locking hubs and on F250 Heavy Duty and F350 with manual locking hubs, use Spanner Lock Nut Wrench (D85T-1197-A) to remove outer lock nut. (Scheme 18) Remove lock washer. Using Spanner Lock Nut Wrench (D85T-1197-A), remove inner lock nut. Remove outer wheel bearing and rotor.
5. On Bronco and F150/F250 Light Duty with manual locking hubs, use Spanner Lock Nut Wrench (T86T-1197-A) to remove wheel bearing adjusting nut. Remove outer wheel bearing, and then rotor.

Scheme 17

Removing Outer Lock Nut (Bronco & F150 W/Auto Locking Hubs, F250 H.D. & F350 W/Manual Locking Hubs). Scheme 18

1. On Bronco and F150 with automatic locking hubs and on F250 Heavy Duty and F350 with manual locking hubs, install rotor and outer wheel bearing. Install inner lock nut. While rotating disc back and forth, seat bearing by using Spanner Lock Nut Wrench (D85T-1197-A) to tighten inner lock nut to 50 ft. lbs. (68 N.m). Back off inner lock nut, and retighten to 30-40 ft. lbs. (41-54 N.m).
2. Install lock washer so key is in spindle groove. Tighten inner lock nut to engage lock nut pin in nearest lock washer hole. Install outer lock nut, and tighten to 160-205 ft. lbs. (217-278 N.m). Spindle end play should be less than.004" (.10 mm).
3. On Bronco and F150/250 Light Duty with manual locking hubs, install rotor and outer wheel bearing. Install adjusting nut. While rotating disc back and forth, seat bearing by using Spanner Lock Nut Wrench (T86T-1197-A) to tighten adjusting nut to 70 ft. lbs. (95 N.m).
4. Back off adjusting nut 90 degrees, and retighten to 15-20 ft. lbs. (20-27 N.m). Spindle end play should be zero. To install remaining hub body components, reverse removal procedure. (Scheme 16)

Removal ("F" Series Super Duty)

1. Set parking brake, and loosen axle shaft bolts. Raise rear of vehicle, and place on jack stands. Release parking brake. Remove and discard axle shaft attaching bolts and washers. Use heavy duty wheel dolly to lift wheel, taking weight off wheel bearings.
2. If dolly is not available, remove wheel assembly. Remove axle shaft, and discard gasket. Remove disc brake caliper. Refer to «DISC BRAKE CALIPERS & PADS»(/ford/econoline-e350/1985-1999/remont/mechanical-hydraulic/#disc-drum) under REMOVAL & INSTALLATION. Using Hub Wrench (T88T-4252-A), remove wheel bearing hub nut. (Scheme 19) Remove outer bearing. Remove hub and rotor assembly. To remove rotor from hub, remove 10 External Torx (E-18) head machine screws.

Scheme 19

1. Put electrical wiring over axle housing spindle to prevent damage. Apply sealant to hub-to-rotor screws. Place hub and rotor assembly onto axle housing spindle. Remove electrical tape. Install outer wheel bearing race and bearing. Install hub nut, ensuring hub nut tab is in hub tab slot before starting threads.
2. Use Hub Wrench (T88T-4252-A) to tighten hub nut. Push inward on socket to prevent ratcheting action of hub nut. Rotate hub while tightening hub nut to 65-75 ft. lbs. (88-102 N.m). Back off hub nut 90 degrees, and retighten to 15-20 ft. lbs (20-27 N.m). End play of hub and rotor should be zero.

Note. Hub nuts are right-hand thread on both sides. Each hub is stamped RH to show thread direction. DO NOT use power impact tools to remove or install hub nuts. Hub nuts will ratchet unless Hub Wrench (T88T-4252-A) is used for removal and installation.

Removal & Installation

Remove wheel assembly, drum and brake shoes. Remove wheel cylinder connecting links. Disconnect hydraulic brake line from cylinder. Remove wheel cylinder retaining bolts and lock washers. Remove wheel cylinder from backing plate. To install, reverse removal procedure. Adjust brakes, and bleed hydraulic system. Refer to BLEEDING BRAKE SYSTEM .

1. On "F" Series Super Duty, with engine off, pump brake pedal several times to discharge hydro-boost accumulator. On all others, disconnect brake warning light indicator wire from indicator switch. With engine off, depress brake pedal to bleed vacuum from brake booster.
2. On all models, disconnect brake lines at master cylinder. Remove nuts retaining master cylinder to brake booster. Remove master cylinder. To install, reverse removal procedure. Bleed brake system. See «BLEEDING BRAKE SYSTEM»(/ford/econoline-e350/1985-1999/remont/mechanical-hydraulic/#disc-drum__bleeding-brake-system) .

Removal & Installation (All Except "F" Series Super Duty)

1. Disconnect stoplight switch to prevent battery discharge. Support master cylinder. Remove vacuum hose from booster check valve. Remove master cylinder mount nuts. Pull master cylinder away from booster to allow booster removal.
2. From inside cab, remove cotter pin holding stoplight switch to brake pedal arm. (Scheme 20) Remove bushing and spacers. Remove booster mount nuts, and then remove booster. To install, reverse removal procedure.

Scheme 20

Removal & Installation ("F" Series Super Duty)

1. With engine off, pump brake pedal several times to discharge accumulator. Remove master cylinder from hydro-boost, and prop aside.
2. Disconnect 3 hydraulic lines from hydro-boost. Disconnect input push rod from brake pedal. Remove 4 hydro-boost mount nuts, and then remove hydro-boost. To install, reverse removal procedure. Bleed power steering system.

1. Shift transmission into gear, and disconnect parking brake cable. Pedal or lever must be in fully released position. Set vehicle on jack stands. Disconnect speedometer cable. Remove bolts attaching driveshaft to parking brake assembly output flange.
2. Remove driveshaft, and secure aside. Remove bolts attaching parking brake assembly to transmission extension housing. (Scheme 21) Remove assembly from transmission.

Scheme 21

Using 6 new bolts, attach parking brake assembly to transmission extension housing. Fill parking brake assembly to bottom of fill hole with Motorcraft MERCON multipurpose automatic transmission fluid. To complete installation, reverse removal procedure.

Removal

Disconnect wire harness from connector. Remove hairpin clip. Slide stoplight switch, booster push rod, washer and bushing away from brake pedal arm. Since stoplight switch side plate nearest brake pedal arm is slotted, booster push rod and one spacer from pedal arm do not need removal. (Scheme 22)

Scheme 22

Position switch so slotted side is facing pedal arm. Swing switch up and down, trapping booster push rod between switch side plates. Push switch and push rod firmly against pedal arm. Install remaining parts, and check stoplight operation.

HEIGHT SENSING PROPORTIONING VALVE

1. With rear wheels on ground, lift frame to obtain 6 5/8" of clearance between bottom edge of rubber jounce bumper and top axle housing on both sides. (Scheme 8) Use this position to install pre-indexed height sensing proportioning valve. CAUTION: Aftermarket load leveling kits, air shocks or modifications which change curb ride height and/or spring deflection rate provide false readings to height sensing proportioning valve. These modifications may result in unsatisfactory brake performance, which in turn could result in an accident.
2. Remove linkage arm mount nut, and remove linkage arm. Disconnect brake line from valve. Remove height sensing proportioning valve mount bolts. Remove height sensing proportioning valve. To install, reverse removal procedure. Bleed system. Refer to «BLEEDING BRAKE SYSTEM»(/ford/econoline-e350/1985-1999/remont/mechanical-hydraulic/#disc-drum__bleeding-brake-system).

Note. When servicing other rear suspension components, remove 2 nuts attaching height sensing proportioning valve linkage to rear axle cover plate, thus eliminating need to replace height sensing proportioning valve.

Removal & Installation (7.3L Diesel)

Remove hose from vacuum pump outlet. Remove vacuum pump belt. Remove pivot and adjustment bolts. Remove vacuum pump. To install, reverse removal procedure. Brake warning light comes on until vacuum builds up to normal level.

Note. Vacuum pump is serviced only as a unit. Vacuum pump pulley can be replaced separately.

Low vacuum switch on E250/350 is located on left front fender. On F250/350, switch is mounted next to vacuum pump. Disconnect vacuum hose from vacuum switch. Remove 2 attaching screws, and remove switch. To install, reverse removal procedure.

CABLE TENSION RELEASE

Note. If any parking brake system component needs to be removed, parking brake cable tension must be released.

Releasing Cable Tension (Except Aerostar)

Have an assistant pull on intermediate cable until all cable is unwound from parking brake foot pedal assembly. Insert a 5/16 inch drill bit or equivalent into hole in foot pedal assembly. (Scheme 23) Disconnect front cable from cable connector under vehicle. Disconnect barrel end of cable from foot pedal assembly. Compress conduit snap fitting and pull cable from foot pedal assembly.

Scheme 23

Scheme 24

1. Remove boot cover from parking brake control lever. Place control lever in released position. Insert a steel pin through pawl lock-out pin hole. (Scheme 24)
2. Insert pin from inboard side at a slightly upward and forward angle and sweep downward and rearward to move self-adjusting pawl. This procedure locks out self-adjusting pawl.
3. Raise vehicle with helper inside on hoist. Pull rearward on equalizer about 1-2 1/2" (25.4-57.1 mm), rotating self-adjuster reel backward.
4. With equalizer pulled rearward, have helper inside vehicle insert a steel pin through self-adjusting spring lock-out holes in lever arm and lever body, locking ratchet wheel in cable released position.

Resetting Cable Tension (Aerostar)

Connect parking brake cables to equalizer. Remove steel pin from spring lock-out hole, keeping fingers clear. Remove steel pin from pawl lock-out hole, restoring tension to parking brake cable. Apply and release parking brake several times to set cable tension.

Scheme 25

1. Parking brake control assembly spring tension is lost when coil spring unwinds and disengages from tab on wheel. This occurs when a cable breaks, when servicing system without inserting lock pin or if lock pin is removed before brake cables are connected.
2. Remove parking brake control lever assembly. Hook end of coil spring on wheel tab. (Scheme 25) Insert a steel pin through pawl lock-out pin holes. Insert pin from inboard side at a slightly upward and forward angle and sweep downward and rearward to move self-adjusting pawl. This procedure locks out self-adjusting pawl.
3. Slip a spare front cable around pulley. Insert cable anchor pin into pivot hole in ratchet plate assembly. With cable on floor, place foot on cable, or clamp end of cable in a vise.
4. Pull on brake control assembly, holding mounting bracket tightly against body of control assembly. Pull until cable tension rotates cable track in order to fully insert lock pin. Insert lock pin so control assembly is in released position. Install parking brake control lever assembly.

DISC BRAKE CALIPER

Note. Use same disassembly procedures for single and dual piston calipers.

Scheme 26

1. Remove caliper. See «DISC BRAKE CALIPERS & PADS»(/ford/econoline-e350/1985-1999/remont/mechanical-hydraulic/#disc-drum) under REMOVAL & INSTALLATION. Drain fluid from caliper. Secure caliper in a vise. Place a block of wood between caliper and piston(s). (Scheme 26) Apply low air pressure to brake hose inlet. Air pressure forces piston(s) outward. CAUTION: DO NOT place fingers between wood and piston as piston leaves caliper.
2. If piston is jammed or seized and does not come out easily, use a brass hammer to lightly tap caliper while applying air pressure. DO NOT pry piston from bore. After piston comes out, remove seal and dust boot. Discard seals and boots.

Cleaning & Inspection

1. Carefully clean rust and corrosion from caliper machined surfaces using a wire brush. DO NOT get wire brush in cylinder bores. Clean all components with isopropyl alcohol, and dry with compressed air.
2. Inspect cylinder bore, seal grooves and boot grooves for wear or damage. If bores are scored, corroded or worn, replace caliper. Replace anti-rattle clip, caliper support spring and key.

Reassembly

1. Lubricate piston seal with clean brake fluid, and install in cylinder bore groove. Lubricate cylinder with clean brake fluid. Coat piston and outside beads of dust boot with clean brake fluid.
2. Push piston through boot until boot is around bottom (closed end) of piston. (Scheme 27)and (Scheme 28). Position piston and boot directly over cylinder bore. Spread dust boot over piston as it is installed.
3. With bead seated in groove, carefully press straight down on piston until it bottoms in cylinder bore. DO NOT cock or jam piston in cylinder. If necessary, use a "C" clamp and a block of wood to bottom piston in cylinder.

Exploded View Of Single Piston Caliper (Bronco, E150 & F150; Others Similar). Scheme 27

Scheme 28

Note. Aerostar recessed cartridge master cylinder cannot be overhauled; replace complete assembly if excessive wear or damage is apparent.

Disassembly

1. Remove master cylinder. Clean outside of master cylinder. Remove filler cap and diaphragm. Drain any remaining fluid from cylinder. On dual master cylinder used on Bronco and "E" & "F" Series vehicles, remove stop bolt from bottom of master cylinder.
2. On all models, remove proportioning valve (if equipped). Depress piston, and remove snap ring from end of master cylinder bore. (Scheme 29)and (Scheme 30). Remove piston assembly from cylinder bore. Carefully apply air pressure in outlet port of cylinder to remove remaining piston assembly from bore.

Note. Manufacturer does not recommend honing of cylinder bore.

Inspection

Clean all parts with isopropyl alcohol, and blow dry with compressed air. Ensure all ports and vents are open and free of foreign matter. Inspect master cylinder bore and all parts for excessive wear or damage. If bore is damaged, replace master cylinder.

Lubricate all components, including cylinder bore, with clean brake fluid. Install new grommets and plastic reservoir. Carefully insert piston assembly into master cylinder bore. If cylinder is equipped with piston stop pin, depress piston, and install pin. Install other piston assembly into cylinder. Depress piston, and install snap ring in groove.

Exploded View Of Master Cylinder Assembly (Aerostar, Explorer & Ranger). Scheme 29

Exploded View Of Master Cylinder Assembly (Bronco, "E" & "F" Series). Scheme 30

Lateral Runout (Front & Rear Disc)

1. On front disc brakes, tighten wheel bearing adjusting nut to eliminate bearing end play. Ensure rotor can be rotated by hand. When checking runout on rear disc brakes ("F" Series Super Duty only), make sure rear axle bearings are adjusted properly.
2. Once adjusted, do not change rear bearing setting. Attach dial indicator to suspension, with indicator tip set one inch from outer edge of rotor face. Set dial indicator to zero, and slowly turn rotor. Take reading within a 6.00" (152.4 mm) radius on rotor. Runout must not exceed specification. See «DISC BRAKE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical-hydraulic/#disc-drum) at end of article. Resurface or replace rotor as required.

Parallelism

1. Parallelism can be tested by 2 testing procedures. Using a micrometer, measure rotor thickness at 12 points, approximately 30 degrees apart and 1.00" (25.4 mm) from outer edge of rotor. Difference must not exceed specification. See «DISC BRAKE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical-hydraulic/#disc-drum) at end of article. Resurface or replace rotor as required.
2. Mount rotor on a brake lathe. Attach 2 dial indicators, one on each side of rotor, with tip of indicators contacting rubbing surface of rotor directly opposite each other and 1.00" (25.4 mm) from outer edge of rotor. Zero both indicators, and rotate rotor. Note indicator reading. If reading exceeds specification, resurface or replace as required. See «DISC BRAKE SPECIFICATIONS»(/ford/econoline-e350/1985-1999/remont/mechanical-hydraulic/#disc-drum) .

Discard Thickness

Using micrometer, measure thickness of rotor. Disc brake rotors have a minimum wear thickness. Minimum wear thickness is not refinishing dimension. See DISC BRAKE SPECIFICATIONS at end of article.

Scheme 31

1. To measure maximum allowable stock remaining for refinishing on inner rotor face, use Disc Rotor Surface Gauge And Ball (T71P-1102-A). (Scheme 31) Remove inner grease seal and bearing from rotor. Wipe inner and outer bearing cups clean.
2. Carefully place gauge ball in inner bearing cup. DO NOT drop. Set micrometer at base line setting number. Using a 2 1/8" (54 mm) gauge ball, base line setting is.256" (6.50 mm). Position micrometer gauge bar on inner rotor face with micrometer centered over gauge ball.
3. To measure distance between micrometer base line setting and gauge ball, turn micrometer down to touch top of ball. Calculate difference between reading and base line setting; difference is maximum allowable stock which can be removed from inner rotor face.
4. When micrometer is set at base line setting and micrometer end touches top of ball, no additional material may be removed from rotor. If micrometer must be retracted from base line setting to allow gauge bar legs to rest on rotor face, rotor has been refinished beyond allowable limit. Replace rotor.

With wheel cylinder removed from vehicle, remove rubber boots from ends of cylinders. Remove pistons, piston cups, return spring and piston expander from cylinder. Remove bleeder screw. Inspect cylinder bore for damage.

If cylinder bore is lightly pitted or scratched, hone or replace as necessary. Coat all parts with clean brake fluid. To assemble, reverse disassembly procedures. Clamp brake cylinder pistons against ends of cylinder.

Scheme 32

1. Remove parking brake assembly. Refer to «TRANSMISSION MOUNTED PARKING BRAKE»(/ford/econoline-e350/1985-1999/remont/mechanical-hydraulic/#disc-drum) under REMOVAL & INSTALLATION. Mount parking brake assembly in vise using brass jaw protectors. Using Lock Nut Socket (T70T-4252-D), remove lock nut from mainshaft. Using a 3-jaw puller or a press with Adapter, remove mainshaft, brake drum and output flange. (Scheme 32) (Scheme 32): Removing Lock Nut, Mainshaft, Brake Drum & Output Flange ("F" Series Super Duty)
2. Remove snap ring holding speedometer drive gear onto shaft, and then remove speedometer drive gear. Using Puller (D80L-1002-L) with Bearing Cone Remover (D79L-4621-A) and Step Plate (D80L-630-6), remove inner bearing cone from mainshaft.
3. Remove parking brake assembly from vise. Turn brake assembly over, and mount threaded end of mainshaft in vise using brass jaw protectors. Remove 4 nuts attaching output flange and brake drum to output shaft. Remove brake drum and flange from output shaft. NOTE: Drum, flange and mainshaft are balanced as a unit. They must be marked to ensure parts are assembled in same position.
4. Using Bearing Cup Puller (T77F-1102-A), remove output shaft oil seal, spacer, "O" ring, bearing and bearing cup from input shaft end of case. Remove splash shield and brake assembly from case. (Scheme 33) Remove brake actuating lever and lever spring from case.
5. Using Bearing Cup Puller (T77F-1102-A), remove outer bearing cup. Unscrew and remove vent from case.

Removing Splash Shield & Brake Assembly ("F" Series Super Duty). Scheme 33

Scheme 34

Scheme 35

1. Using Bearing Cup Installer (T88T-2598-E), install bearing cup into case. Install inner bearing. Apply a light coat of sealer to outer edge of oil seal. Place oil seal in case with sealing lip facing inward. Press seal into case flush with bore surface using Seal Installer (T88T-2598-C).
2. Install actuating lever spring on boss in case. (Scheme 34) Apply a light coat of lithium base grease to actuating lever ball. Install ball end of lever into hole in boss through coiled end of spring. Position backing plate and brake assembly onto case. (Scheme 34): Installing Lever Spring, Actuating Lever, Backing Plate & Brake Assembly ("F" Series Super Duty)
3. Insert actuating lever (cam end) into position in brake assembly. Install and tighten brake assembly mount bolts. Attach return spring to actuating lever, and bend long end of spring to snap over lever. Place mainshaft with flanged end up in vise using brass jaw protectors.
4. Install brake drum and output flange onto flanged end of mainshaft. Install output flange onto brake drum, aligning marks made during disassembly. Proper installation maintains proper component balance. Install and tighten output flange mount nuts. Remove mainshaft and drum assembly from vise. Turn assembly over, and clamp in vise again.
5. Install case onto mainshaft, guiding shaft through oil seal and bearing. Using Bearing Installer (T88T-2598-F), seat output bearing onto mainshaft. Install speedometer drive gear and snap ring onto mainshaft. Using Bearing Cup Installer (T88T-2598-D), install input bearing cup into housing. NOTE: Mainshaft shim determines end play. Shims are available in thicknesses of.0019" (.048 mm).
6. Install shim on mainshaft. Install inner bearing onto mainshaft. To measure end play, install bearing spacer, without "O" ring, onto mainshaft. Clamp case assembly and mainshaft in vise. Use Lock Nut Socket (T70T-4252-D) to screw hex nut onto mainshaft.
7. Mount a dial indicator between mainshaft and case. While rotating case assembly on mainshaft to center bearings, apply up and down pressure to take a reading. End play should be.0019-.0039"(.048-.099 mm). Select proper shim to reach specified end play.
8. Coat outer surface of new input oil seal with sealant. Install oil seal into case with sealing lip facing inward. Press seal in until it is fully seated. Install a new "O" ring in notch of bearing spacer. (Scheme 35) Install "O" ring and bearing spacer onto mainshaft until spacer butts against input bearing.
9. Use Lock Nut Socket (T70T-4252-D) to install a new lock nut onto shaft. Screw vent into case. Remove parking brake assembly from vise. Install onto vehicle. Fill case with Motorcraft MERCON multipurpose automatic transmission fluid. Fill to bottom of fill hole. To install remaining components, reverse removal procedure.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

DISC BRAKE SPECIFICATIONS

DISC BRAKE SPECIFICATIONS

DRUM BRAKE SPECIFICATIONS

DRUM BRAKE SPECIFICATIONS

See also:
• BLEEDING SEQUENCE
• BLEEDING SEQUENCE
• BLEEDING BRAKE SYSTEM