Disc Brake System & Drum Brake System Ford Econoline I

DESCRIPTION & OPERATION

Note. This article also applies to Cab & Chassis.

Note. References to F250/350 also apply to super duty models, except where noted.

Brake Booster

All models are equipped with a dual-diaphragm vacuum booster. Boosters are self-contained, vacuum power brake units. Booster assists in actuating master cylinder push rod.

Booster contains a dual vacuum-suspended diaphragm which uses engine manifold vacuum or atmospheric pressure for power. Diesel models 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.

An equalizer valve links 2 chambers of brake booster. When valve opens, vacuum in chambers can equalize. When it closes, chambers are separated. A vacuum bleed valve functions to reduce amount of vacuum in secondary chambers when boost is required.

Super Duty Pickup uses a Hydro-Boost system. Hydro-Boost is hydraulically operated by 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.

Deactivator Switch

On Van with speed control, a deactivator switch is located underneath brake master cylinder as an additional safety feature. Normally, when brake pedal is depressed, an electrical signal from brakelight circuit to speed control amplifier will turn off system. Under increased brake pedal efforts, deactivator switch mounted on master cylinder will open and remove power to speed control actuator clutch, releasing throttle independent of speed control amplifier.

Front Disc Brakes

Front disc brakes are standard on all models. A dual piston front caliper assembly is used on all models except E150.

Rear Disc Brakes

Rear disc brakes are standard or optional on all models except E150/E250, E350 1998, and Ranger. Super Duty Pickup and E350 1999 use dual piston rear caliper. All other models use single piston caliper. All models are equipped with full-cast rear disc brake rotors and a cable-actuated, single-anchor, shoe type parking brake.

Rear Drum Brakes

Rear drum brakes are used on E150/E250, E350 1998, some F150/F250 models, Ranger, and some Windstar models. 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. Brake shoe linings are made of asbestos-free, fiberglass material. Rear drum brake assembly consists of a support plate, 2 brake shoes, return springs, automatic adjuster components and one dual-piston wheel cylinder. Brake drums are available in 9" and 10" sizes.

Master Cylinder

Models are equipped with dual master cylinder with primary and secondary pistons.

Vacuum Pump (Diesel)

Vacuum is supplied from a belt-driven vacuum pump. Diesel equipped vehicles use a low vacuum indicator switch. Indicator switch is located on left side of engine compartment, near vacuum pump. Indicator switch will turn on brake warning lamp when a low vacuum situation occurs.

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 brakelines in sequence. See BLEEDING SEQUENCE .

MANUAL BLEEDING

Note. DO NOT allow reservoir to run dry during bleeding operation.

Master Cylinder Bleeding (Bench)

1. Support brake master cylinder body in a vise, and fill both fluid brake master cylinder reservoirs with brake fluid. Install plugs in front and rear brake outlet ports. Bleed front brake system first. Loosen plug in front brake outlet port and depress primary piston slowly to force air out of master cylinder.
2. Tighten plug while piston is depressed or air will enter brake master cylinder. Repeat procedure until no air bubbles are present. Repeat bleeding procedure for rear brake outlet port with front brake outlet plugged. Tighten plugs and try to depress piston. Piston will not depress if all air is out of master cylinder.

Master Cylinder Bleeding (On-Vehicle)

1. Using a tubing wrench, remove front brake tube and master cylinder outlet rear tube from master cylinder. Install short brake tubes in master cylinder and position them so they curve into master cylinder reservoir, and ends of tubes are submerged in brake fluid.
2. Fill master cylinder reservoir with clean brake fluid. Have an assistant pump brakes until clear, bubble-free fluid flows from both brake tubes. Remove short brake tubes and reinstall front brake tube and master cylinder inlet rear tube on master cylinder. Bleed each brake tube at master cylinder by having and assistant pump brake pedal 10 times and then hold firm pressure on brake pedal.
3. Loosen rearmost brake tube fittings until a stream of brake fluid comes out. Have an assistant maintain pressure on brake pedal until brake tube fitting is tightened again. Repeat procedure until clear, bubble-free fluid comes out from around tube fitting. Refill master cylinder reservoir as necessary. Repeat this bleeding operation at front brake tube fittings.

Gravity Bleeding

Fill brake master cylinder with new brake fluid. Loosen both of wheel cylinder bleeder screws and leave them open until clear brake fluid flows. Be sure to check master cylinder reservoir fluid level often and do not let it run dry. Tighten wheel cylinder bleeder screws. One at a time, loosen caliper bleeder screws. Leave bleeder screws open until clear fluid flows. Check fluid level often. Tighten caliper bleeder screws.

Scheme 1

1. Clean master cylinder cap and surrounding area. Remove cap. All models are equipped with dual-type master cylinder. Bleed primary and secondary systems separately. Loosen primary or secondary master cylinder hydraulic line fitting. (Scheme 1)
2. Wrap a cloth around brakelines to absorb escaping brake fluid. 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. Repeat procedure at bleeder fitting on rear anti-lock brake electrohydraulic RABS Valve, each wheel cylinder and caliper. (Scheme 2) See «BLEEDING SEQUENCE»(/ford/econoline/i-1985-2013/remont/mechanical-hydraulic/#disc-brake-system-drum-brake-system) table under BLEEDING SEQUENCE. When bleeding is complete, fill master cylinder to proper level.

Scheme 2

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.
2. Open pressure bleeder valve. Bleed master cylinder primary and secondary hydraulic lines individually. Put shop towels in place to catch brake fluid.
3. Open lines. 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 2) See «BLEEDING SEQUENCE»(/ford/econoline/i-1985-2013/remont/mechanical-hydraulic/#disc-brake-system-drum-brake-system) table 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 cylinder and calipers in sequence. See «BLEEDING SEQUENCE»(/ford/econoline/i-1985-2013/remont/mechanical-hydraulic/#disc-brake-system-drum-brake-system) table.
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 table.

BLEEDING SEQUENCE

BLEEDING HYDRO-BOOST UNIT

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

Super Duty Pickup

1. Fill power steering pump reservoir with MERCON multipurpose automatic transmission fluid. Remove power train control module (PCM) fuse and crank engine for several seconds. Check and add fluid if necessary. Install PCM fuse. 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.

ADJUSTMENTS

VACUUM POWER BOOSTER PUSH ROD

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 groaning noise in booster area.
2. Remove master cylinder to access push rod. To check screw adjustment, fabricate a gauge. (Scheme 3)and (Scheme 4). With engine running, 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.

Scheme 3

Scheme 4

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 5)

Scheme 5

BRAKE PEDAL FREE HEIGHT (WINDSTAR)

1. Start engine, ensure transaxle is in Park or Neutral, block wheels and fully release parking brake. Insert a slender, sharp-pointed prod through floor carpet and sound deadener to dash panel metal. Measure distance to center on top accelerator pedal side of brake pedal pad. If position of brake pedal is not within a maximum of 6.5" (165 mm) and a minimum of 6.3" (160 mm), check brake pedal bracket for missing, worn, or damaged bushings, of loose retaining bolts and replace if required.
2. Dimension "B" should be measured parallel to vertical center line of steering column with a 25 lbs. (11.3 kg) load applied to center line of brake pedal pad. (Scheme 6) If brake pedal free height is still out of specification, check brake pedal, power brake booster, or brake master cylinder to be sure correct parts are installed. Replace worn, damaged or incorrect parts as necessary.

Scheme 6

BRAKE PEDAL TRAVEL (WINDSTAR)

1. Start engine, ensure transaxle is in Park or Neutral, block wheels and fully release parking brake. Hook a steel measuring tape to brake pedal. Measure and record distance from brake pedal free height position to reference point, which is at six o'clock position on steering wheel rim. (Scheme 7) With steel tape still hooked to brake pedal, apply a 25 lbs. (11.3 kg) load to center of brake pedal.
2. Maintain brake pedal load and measure distance from brake pedal to fixed reference point on steering wheel rim parallel to center line of steering column. (Scheme 7) Difference between brake pedal free height and depressed pedal measurement under a 25 lbs. (11.3 kg) load should be 2.76" (70 mm) maximum. If brake pedal travel is more than maximum dimension specification, make several reverse stops with a forward stop before each.
3. Move vehicle backward and forward for about 10 feet. Then apply brakes holding brake pedal down until vehicle is completely stopped. This will actuate rear brake shoe and lining self-adjusters. If these stops do not bring brake pedal travel within specification, make several additional forward and backward stops. If this does not bring brake pedal travel within specification, bleed brake system.

Scheme 7

Parking Brake Shoe Adjustment (Expedition, Explorer, Mountaineer & Super Duty Pickup)

Note. On all models except Expedition, Explorer, Mountaineer and Super Duty Pickup, parking brake system is self-adjusting and does not require adjustment.

Using Brake Adjustment Gauge (D81L-1103-A), measure inside diameter of drum portion of rear disc brake rotor. On Super Duty Pickup, using parking brake adjuster screw, adjust parking brake shoe and lining until they drag against parking brake drum. On Expedition, Explorer and Mountaineer, adjust parking brake shoe and lining to .020" (.508 mm) less than drum measurement.

Drums Removed

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 8

1. Adjust with brake drums cold and parking brake correctly adjusted. Measure brake drum inside diameter using brake shoe adjustment gauge. (Scheme 8)
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 8)
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.

TROUBLE SHOOTING

Note. Occasional brake squeal can be caused by environmental conditions such as cold ambient temperatures, heat, rain, snow salt, mud, hot ambient temperatures or high humidity. This occasional squeal is not a functional problem and does not indicate any loss in brake effectiveness.

INSPECTION

1. Visually examine front and rear tire and wheel assemblies for damage such as uneven wear, tread washouts, or side-wall damage. Make sure tires are of same size, type and same manufacturer (where possible). Any tire or wheel that is damaged should be replaced. Wheels and tires must be cleared of any foreign matter and tire pressures adjusted to correct specifications.
2. If tires exhibit uneven wear or feathering, cause must be corrected. Check steering and suspension components for damage or wear and check and adjust steering alignment (if necessary). Check hydraulic hoses and tubes for leaks, cracks, chaffing and distortions. Check fasteners that hold these components in place should also be checked.
3. Check drum brakes for loose or worn parts. Check rear wheel cylinder for leakage around dust boot. Check for proper component installation, leakage, caliper slide lubrication and excessive wear along caliper supports. Check instrument cluster brake warning light.
4. Check that link from brake load sensor proportioning valve to frame is properly connected. Brake load sensor proportioning valve is calibrated for particular vehicle it is installed on. If modifications are made to rear suspension system, brake load sensor proportioning valve will not work properly and must be deactivated.

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. Check for leaks or air in system.

Pedal goes down slowly

1. Check for external or internal leaks.

Pedal is low and/or feels spongy

1. Check for 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 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.

To check master cylinder for internal leak, disconnect brake lines at master cylinder. Plug outlet ports of master cylinder. Apply brakes. If pedal height cannot be maintained, master cylinder has internal leak and must be rebuilt or replaced.

BRAKE WARNING LIGHT

1. Brake warning light should only come on when ignition switch 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 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, 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 switch 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 brake pedal is low or bottoming out, 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, increase 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.

1. Turn key off, disconnect vacuum line and connect a vacuum gauge with a "T" fitting to lower part of dash mounted plastic check valve. (Scheme 9) Start engine and allow to run at idle until vacuum reaches 17-21 in. Hg.
2. Turn ignition off and observe vacuum gauge for one minute. If vacuum drops more than one in. Hg, replace power brake booster check valve. If vacuum does not drop more than one in. Hg, go to next step.
3. Reconnect vacuum gauge in same point as in step 1, but leave rest of system connected. Start engine and allow engine to run at idle until vacuum reaches 17-21 in. Hg. Turn key off and observe vacuum gauge for one minute.
4. If vacuum drops more than one in. Hg, disconnect each component one at a time and repeat test procedures in step 3 until leaking component is found. Plug disconnected vacuum line while performing test procedures. Repair or replace defective component as required. On diesel engine with dash mounted power brake booster, replace power brake booster check valve also. If vacuum does not drop more than one in. Hg, go to next step.
5. Start engine and run engine until vacuum reaches 17-21 in. Hg. Turn ignition off and push down on brake pedal for a few seconds and release. If vacuum pressure drops to zero in. Hg, replace power brake booster. If vacuum pressure does not drop to zero in. Hg, system is okay. Remove vacuum gauge and reconnect all vacuum lines.

Scheme 9

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.

Hydraulic Pressure Tests

1. Check for hydraulic leaks in system. Check power steering pump does not exhibit sustained failure or internal damage that may contaminate fluid in system. If there is a possibility of burned fluid or metal particles in fluid, brake system should be purged before connecting power steering analyzer.
2. Connect Power Steering System Analyzer (014-00230). Follow installation procedure supplied with analyzer. Fully open shutoff valve, start engine and purge air from brake system by applying brakes several times. Shut off engine and check connections for leaks.
3. Check for proper fluid level at reservoir and add or remove fluid as required. Recheck for air in system by restarting engine, partially closing shutoff valve and viewing pressure gauge. If gauge needle vibration is excessive, too much air remains in system. Install thermometer in reservoir and connect tachometer to engine.
4. Fully open analyzer shutoff valve. Start engine and run at 2000 RPM. When fluid temperature reaches 130°F (55°C), record flow and pressure. If flow is less than 3.1 gal/min (11.7 L/min), check to see if correct pump is installed. If correct pump is installed, continue testing. If pressure exceeds 25 psi (172 kPa), check lines for kinks or obstructions.
5. Check pump for minimum efficiency flow. Decrease engine speed to 750-850 RPM. Slowly close shutoff valve to build pressure to 1200 psi (8400 kPa). Record flow with temperature at least 130°F (55°C). If flow is less than 1.3 gal/min (5 L/min), check if correct pump is installed. Pump may require repair or replacement, especially if flow in step 4 was also less than value indicated.
6. Check pump for pressure relief valve operation. Run engine at 750-850 RPM. Completely close and partially open shutoff valve 3 times. Read pressure when valve is fully closed. If pressure is less than 1230 psi (8480 kPa), or greater than 1350 psi (9307 kPa), clean or replace pressure relief valve. If pressure is between 1230-1350 psi, pump is operating normally and other areas should be investigated.

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 vacuum at idle with transmission in Neutral. If reading is less than specification, 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 reading is still less than 15-19 in. Hg vacuum, engine is producing low vacuum and mechanical 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 for a few seconds. If vacuum drops to zero, booster is leaking and requires replacement.

VACUUM BOOSTER CHECK VALVE

1. Remove vacuum booster hose from power brake booster and check valve connection. Manifold vacuum should be available at check valve end of vacuum booster hose with engine idling and transmission in Neutral.
2. Operate engine a minimum of 10 seconds at fast idle. Stop engine, and let vehicle stand for 10 minutes. Apply brake pedal with about 20 lbs. (9 kg) of force. Brake pedal feel should be same as that noted with engine operating. If brake pedal feels hard, replace check valve and retest.

REMOVAL & INSTALLATION

Removal & Installation (Diesel)

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

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. (Scheme 9)

FRONT BRAKE ROTOR

Note. If caliper does not require service, it is not necessary to remove brake hose from caliper unless indicated.

Removal (2WD Models)

1. Raise and support vehicle. Remove wheel. Remove anchor plate and caliper assembly, and position aside. See «DISC BRAKE CALIPERS & PADS»(/ford/econoline/i-1985-2013/remont/mechanical-hydraulic/#disc-brake-system-drum-brake-system__disc-brake-calipers-pads). On all models except Windstar, remove grease cap, cotter pin, nut, washer and outer bearing. (Scheme 10) Remove rotor. Remove inner bearing, and grease seal.
2. On Windstar, remove rotor bolts and remove rotor.

On all models except Windstar, inspect and thoroughly clean front wheel bearings, hub and rotor. Lubricate front wheel bearings with appropriate grease. If excessive force was necessary during removal, check brake rotor total indicated runout (TIR), prior to installation. See ROTOR under OVERHAUL.

Installation (Expedition, Pickup & Navigator 2WD)

1. Install inner bearing and NEW grease seal. Position rotor. Install outer wheel bearing, and bearing retainer washer. Position spindle nut. (Scheme 10)
2. To seat bearings, while rotating rotor clockwise, tighten spindle nut to 30 ft. lbs. (40 N.m). Loosen spindle nut 2 full turns. While rotating rotor counterclockwise, tighten spindle nut to 17-24 ft. lbs. (23-34 N.m). Back off spindle nut 175 degrees. To complete tightening procedure, rotate rotor clockwise while tightening spindle nut to 17 INCH lbs. (2 N.m).
3. To complete installation, install spindle nut retainer, NEW cotter pin, and grease cap. Install anchor plate and caliper assembly. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/mechanical-hydraulic/#disc-brake-system-drum-brake-system__torque-specifications).

Scheme 10

1. Install inner bearing and NEW grease seal. Position rotor assembly. Install outer wheel bearing, and bearing retainer washer. Position spindle nut. (Scheme 10)
2. To seat bearings, while rotating rotor counterclockwise, tighten spindle nut to 17-24 ft. lbs. (23-34 N.m). Back off spindle nut 175 degrees. To complete tightening procedure, rotate rotor clockwise while tightening spindle nut to 17 INCH lbs. (2 N.m).
3. To complete installation, install spindle nut retainer, NEW cotter pin, and grease cap. Install anchor plate and caliper assembly. Tighten bolts to specification. (Scheme 10) See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/mechanical-hydraulic/#disc-brake-system-drum-brake-system__torque-specifications).

Installation (Van)

1. Install inner bearing and NEW grease seal. Position rotor. Install outer wheel bearing, and bearing retainer washer. Position spindle nut.
2. To seat bearings, while rotating rotor clockwise, tighten spindle nut to 29.5 ft. lbs. (40 N.m). Loosen spindle nut 2 full turns. While rotating rotor clockwise, tighten spindle nut to 17-24 ft. lbs. (23-34 N.m). Back off spindle nut 175 degrees. To complete tightening procedure, rotate hub and rotor clockwise while tightening spindle nut to 17 INCH lbs. (2 N.m).
3. To complete installation, install spindle nut retainer, NEW cotter pin, and grease cap. Install caliper anchor plate and caliper. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/mechanical-hydraulic/#disc-brake-system-drum-brake-system__torque-specifications) .

Installation (Windstar)

Install rotor. Install and tighten rotor bolts to 106 INCH lbs. (12 N.m). Install anchor plate and caliper assembly. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

Removal & Installation (4WD Models - Except Super Duty Pickup)

1. Raise and support vehicle. Remove wheel. Remove anchor plate and caliper assembly. See «DISC BRAKE CALIPERS & PADS»(/ford/econoline/i-1985-2013/remont/mechanical-hydraulic/#disc-brake-system-drum-brake-system__disc-brake-calipers-pads) . Remove rotor.
2. To install, reverse removal procedure. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/mechanical-hydraulic/#disc-brake-system-drum-brake-system__torque-specifications) .

Removal (Super Duty Pickup - 4WD)

Raise and support vehicle. Remove wheel. Remove anchor plate and caliper assembly. See DISK BRAKE CALIPERS & PADS. On models with single rear wheels, remove rotor. On models with dual rear wheels, remove hub plate extender nuts, and remove hub extender plate. (Scheme 11) Remove rotor.

Note. If excessive force is used when removing rotor, it should be checked for lateral runout prior to installation. See ROTOR under OVERHAUL.

Scheme 11

Installation

To install, position rotor to hub. Ensure hub and rotor braking surfaces are clean. Install rotor. On single rear wheel models, install anchor plate and caliper assembly. On dual rear wheel models, install hub extender plate and nuts. Install anchor plate and caliper assembly. (Scheme 11) On all models, tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS.

Remove the parking brake control. See PARK BRAKE CONTROL. Disconnect the front parking brake cable from the parking brake control. (Scheme 12) Remove the front parking brake cable and conduit housing. Compress the front parking brake cable and conduit-to-parking brake control clip. Remove the front parking brake cable and conduit housing. To install, reverse removal procedure. Make sure cable is routed through loop on take up spool. (Scheme 13)

Scheme 12

Scheme 13

Note. Make sure the parking brake control is fully released.

1. Relieve the tension on the parking brake system by pulling down on the parking brake intermediate cable and inserting a 5/32" (4 mm) drill bit or equivalent retainer in the parking brake control. (Scheme 14)
2. Remove the drum brake shoes. See «BRAKE SHOES»(/ford/econoline/i-1985-2013/remont/mechanical-hydraulic/#disc-brake-system-drum-brake-system). Disconnect the parking brake intermediate cable from the locating hole end of the connector. Disconnect the parking brake intermediate cable from the left parking brake rear cable and conduit.
3. Separate the right parking brake rear cable and conduit from the left parking brake rear cable and conduit at the parking brake cable equalizer.
4. Remove the right parking brake rear cable and conduit from the parking brake cable bracket by Compressing the parking brake cable clip. Remove the right parking brake rear cable and conduit from the parking brake cable bracket.
5. Remove the left parking brake rear cable and conduit from the rear parking brake cable retainer. Remove the right parking brake rear cable and conduit from the right hydraulic brake line clips.
6. Unclip the parking brake rear cable and conduit from the brake line clip on top of the rear axle housing. Disconnect the parking brake cable from the parking brake lever. Remove the parking brake rear cable and conduit by compressing the retainer fingers. Remove the parking brake rear cable and conduit. To install, reverse the removal procedure.

Note. Make sure the parking brake control is fully released.

1. Relieve the tension on the parking brake system by pulling down on the parking brake intermediate cable and inserting a 5/32" (4 mm) drill bit or equivalent retainer in the parking brake control. (Scheme 14)
2. Remove the left front fender splash shield screws, pushpin, bolts and electrical connector locators. Remove the splash shield.
3. Disconnect the front parking brake cable and conduit at the locating hole end of the connector. Disconnect the front parking brake cable and conduit from the parking brake intermediate cable. (Scheme 15)
4. Remove the front parking brake cable and conduit from the bracket by compressing the retainer from the front parking brake cable and conduit from the bracket. (Scheme 16) Remove the front parking brake cable and conduit from the bracket. Remove the parking brake release mounting bolts. (Scheme 17)
5. Remove the parking brake control and front parking brake cable and conduit by disconnecting the parking brake signal switch electrical connector and removing the three parking brake control bolts. (Scheme 18) To install, reverse removal procedure. Tighten bolts and nuts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/mechanical-hydraulic/#disc-brake-system-drum-brake-system__torque-specifications).

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Removal & Installation (Rear Disc Brakes)

Remove rear brake rotor. See REAR BRAKE ROTOR. Remove brake shoe retracting spring and brake shoe adjusting screw spring. (Scheme 19) Remove brake shoe adjusting screw. Remove brake shoe hold-down springs. Remove parking brake shoes. To install, reverse removal procedure. Adjust parking brake shoes. See PARKING BRAKE under ADJUSTMENTS.

Scheme 19

Removal & Installation (Expedition & Navigator)

1. Raise and support vehicle. Remove wheel. Remove anchor and caliper assembly, and position aside. See «DISC BRAKE CALIPERS & PADS»(/ford/econoline/i-1985-2013/remont/mechanical-hydraulic/#disc-brake-system-drum-brake-system__disc-brake-calipers-pads) . Remove press-on keeper nuts from hub studs (if equipped). Remove rotor.
2. To install, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/mechanical-hydraulic/#disc-brake-system-drum-brake-system__torque-specifications) .

Removal & Installation (Explorer, E150/250, F150/250 & Mountaineer)

Note. On all models except E250 and F250, when removing rear brake rotor, it is not necessary to disconnect hydraulic lines.

1. Raise and support vehicle. Remove wheel. Remove brake hose-to-caliper bolt. Remove and plug brake hose. Remove caliper. See «DISC BRAKE CALIPERS & PADS»(/ford/econoline/i-1985-2013/remont/mechanical-hydraulic/#disc-brake-system-drum-brake-system__disc-brake-calipers-pads) . Remove rotor.
2. Install NEW copper washers when installing brake hose-to-caliper bolt. Tighten bolts and nuts. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/mechanical-hydraulic/#disc-brake-system-drum-brake-system__torque-specifications) . Bleed brakes. See «BLEEDING BRAKE SYSTEM»(/ford/econoline/i-1985-2013/remont/mechanical-hydraulic/#disc-brake-system-drum-brake-system__bleeding-brake-system) .

Scheme 20

1. Raise and support vehicle. Remove wheel. Remove caliper. See «DISC BRAKE CALIPERS & PADS»(/ford/econoline/i-1985-2013/remont/mechanical-hydraulic/#disc-brake-system-drum-brake-system__disc-brake-calipers-pads). Remove caliper anchor plate. Mark wheel stud and corresponding rotor hole to minimize runout when installing. (Scheme 20) Remove rotor bolts. Remove rotor.
2. To install, reverse removal procedure. Align rotor and hub stud marks. Install new brake pads as necessary. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/mechanical-hydraulic/#disc-brake-system-drum-brake-system__torque-specifications).

Removal (Super Duty Pickup - Dual Rear Wheels)

Note. Dana and Ford dual rear wheel axles are used. (Scheme 21) On Ford axles, hub nut is right-hand thread on passenger side (nut stamped "RH"), and left-hand thread on driver side (nut stamped "LH").

1. Set parking brake. Loosen axle shaft retaining bolts. Raise and support vehicle. Release parking brake. Remove wheel. Remove anchor plate and caliper assembly. See «DISC BRAKE CALIPERS & PADS»(/ford/econoline/i-1985-2013/remont/mechanical-hydraulic/#disc-brake-system-drum-brake-system__disc-brake-calipers-pads) . Remove axle shaft retaining bolts and axle shaft.
2. On Dana axle, using socket wrench, remove hub nut. Remove outer bearing. Remove hub and rotor assembly. Remove rotor-to-hub bolts and separate rotor from hub.
3. On Ford axle, using hub nut wrench, and in correct rotation, remove hub nut. Using 2-Jaw Puller (D80L-1002-L), pull hub to point of removal, and secure outer bearing. Remove hub and rotor assembly. Remove rotor-to-hub bolts, and separate rotor from hub.

To install, reverse removal procedure. Install NEW hub seal. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS .

Scheme 21

Removal (Super Duty Pickup - Single Rear Wheels)

Raise and support vehicle. Remove wheel. Remove caliper assembly. See DISC BRAKE CALIPERS & PADS . Remove rotor.

To install, reverse removal procedure. On dual rear wheel models, install NEW hub seal. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS .

Removal & Installation (Windstar)

1. Raise and support vehicle. Remove wheel. Remove anchor plate and caliper assembly and position aside. See «DISC BRAKE CALIPERS & PADS»(/ford/econoline/i-1985-2013/remont/mechanical-hydraulic/#disc-brake-system-drum-brake-system__disc-brake-calipers-pads) .
2. Remove keeper nuts from rotor (if equipped). Remove plug from adjustment hole on back of brake shield. Contract parking brake shoes by turning adjuster clockwise for driver side and counterclockwise for passenger side. Remove rotor from hub. To install, reverse removal procedure.

Removal (Ranger)

1. Raise and support vehicle. Remove brake drum. Inspect rear wheel cylinder for leaks or presence of rust. If no leaks are found, install brake cylinder clamp over ends of rear wheel cylinder. Remove brake shoe retracting springs. Remove brake shoe adjusting lever cable from anchor pin, cable guide and adjusting lever. (Scheme 22)
2. Remove cable guide from secondary brake shoe and lining web. Remove adjusting lever and adjusting lever return spring. Remove brake shoe adjusting screw spring. Using Hold-Down Spring Remover/Installer (T73T-2300-A), remove brake shoe hold-down spring and pin from each rear brake shoe and lining. Remove brake shoe adjuster assembly.
3. Remove primary brake shoe parking brake lever link and parking brake link spring. Remove parking brake rear cable and conduit from parking break lever. Remove rear brake shoe and lining. Remove parking brake lever from secondary rear brake shoe.

Scheme 22

Removal (Windstar)

1. Remove brake drum. Disconnect right parking brake rear cable and conduit or left parking brake rear cable and conduit from parking brake lever. Remove 2 brake shoe hold-down springs and brake shoe hold-down pins.
2. Remove brake shoe adjusting screw spring. Remove brake shoe adjusting lever and brake adjuster screw. Remove brake shoe retracting spring. Remove rear brake shoes and linings from brake backing plate. Remove and discard parking brake lever clip and washer. Remove parking brake lever form secondary rear brake shoe and lining. (Scheme 23)

Scheme 23

Removal (E150 & F150)

1. Remove wheel assembly and drum. If brake drum is difficult to remove, use a narrow screwdriver and brake adjustment tool to retract brake shoes. Place a wheel cylinder clamp over ends of wheel cylinder. Disengage adjusting lever from adjusting screw by pulling backward on lever cable. (Scheme 24)
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 lever retainer and spring washer.

Scheme 24

Removal (E250 & F250 Standard Duty)

Remove wheel assembly and brake drum. If brake drum is difficult to remove, use a narrow screwdriver and brake adjustment tool to retract brake shoes. Remove parking brake lever assembly retaining bolt from backing plate. Remove parking brake lever assembly. (Scheme 25) Remove adjusting cable assembly from anchor pin, cable guide and adjusting lever. Remove brake shoe return springs, hold-down springs and brake shoes. Remove and disassemble adjusting screw assembly.

Scheme 25

Installation (All Models)

1. 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. Ensure brake shoe adjusting lever cable is positioned in groove and not between cable guide and shoe web.
2. Ensure cable end is not cocked or binding on anchor pin when installed. All parts should be flat on anchor pin. Ensure brake adjuster screw is installed in same location from which it was removed.
3. Brake adjusting screw nuts can also be distinguished by number lines machined around body or nut. One line indicates left-hand nut, and 2 lines indicates right-hand nut. Another way to identify adjusters is to check thread pitch. Right side adjuster has right-hand threads while left side adjuster has left-hand threads. To install, reverse removal procedure.
4. On Ranger, check action of adjuster by pulling brake shoe adjusting lever cable toward secondary shoe, activating brake shoe adjusting lever. Brake shoe adjusting lever should snap in above next tooth of adjuster. Release brake shoe adjusting lever cable to return brake shoe adjusting lever to original position and adjuster should turn one notch.
5. If adjusting lever action is sluggish instead of positive and sharp, check position of brake shoe adjusting lever on adjusting screw toothed wheel. Brake shoe adjusting lever should contact adjusting wheel one tooth above centerline of brake adjuster screw.

DISC BRAKE CALIPERS & PADS

Note. Procedure for removing/installing front and rear calipers is same.

Removal

Note. To prevent master cylinder overflow when caliper piston is depressed, remove and discard some brake fluid from master cylinder.

1. Raise and support vehicle. Remove wheel. Remove brake hose-to-caliper bolt. Remove and plug hose. Place a large "C" clamp on caliper. Tighten clamp to bottom piston in cylinder bore. Remove clamp.
2. Remove caliper pin bolts. Remove caliper from rotor. Remove brake pads. Remove anchor plate rail clips. Check brake pad wear.
3. On all models except Super Duty Pickup, replace brake pads if lining is less than .04" (1.0 mm) above backing plate at any point. On Super Duty Pickup, replace pads if lining is less than .06" (1.5 mm) above backing plate or rivets at any point.

Install anchor plate rail clips. Install brake pads. Use "C" clamp to push caliper piston into piston bore until it bottoms out. Position caliper on rotor. Install caliper pin bolts. Connect brake hose to rotor using NEW copper washers on connector bolt. Bleed brakes. See BLEEDING BRAKE SYSTEM .

1. On Super Duty Pickup, 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. Disconnect brakelines at master cylinder. Remove nuts retaining master cylinder to brake booster. Remove master cylinder. To install, reverse removal procedure. Bleed brakes. See «BLEEDING BRAKE SYSTEM»(/ford/econoline/i-1985-2013/remont/mechanical-hydraulic/#disc-brake-system-drum-brake-system__bleeding-brake-system) .

Disconnect wire harness from connector. Remove pin. Slide stoplight switch, brake pedal rod, spacer and bushing away from brake pedal arm. Since stoplight switch side plate nearest brake pedal arm is slotted, brake pedal rod and one spacer from pedal arm do not need removal. (Scheme 26)

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

Scheme 26

Note. Super Duty Pickups use either hydro-boost or vacuum power brake booster.

1. With engine off, depress brake pedal several times to discharge accumulator. Disconnect negative battery cable(s). Remove battery on driver side. Remove air cleaner housing. Disconnect brake pressure switch electrical connector.
2. Disconnect power steering hoses. Remove master cylinder nuts, and remove master cylinder. Remove fuse panel cover. Remove stoplight switch, and brake booster push rod from brake pedal pin. Remove brake booster nuts, and remove booster.

To install, reverse removal procedure. Install NEW Teflon seals on power steering pressure hose fittings. Tighten nuts to specification. See TORQUE SPECIFICATIONS . Bleed booster. See BLEEDING HYDRO-BOOST UNIT under BLEEDING BRAKE SYSTEM.

Note. Super Duty Pickup uses either vacuum or hydro-boost power brake booster.

1. Disconnect negative battery cable. Remove air cleaner assembly. Disconnect speed control and accelerator cables if necessary. Remove speed control module bolts and position speed control aside. Remove vacuum hose from booster check valve.
2. Remove instrument panel lower cover. Remove cotter pin holding stoplight switch to brake pedal arm. (Scheme 27) Remove bushing and spacers. Remove booster mount nuts, and then remove booster. To install, reverse removal procedure.

Scheme 27

Remove wheel assembly, drum and brake shoes. Remove wheel cylinder connecting links. Disconnect hydraulic brakeline 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. See BLEEDING BRAKE SYSTEM .

Disassembly

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

1. Remove caliper. See «DISC BRAKE CALIPERS & PADS»(/ford/econoline/i-1985-2013/remont/mechanical-hydraulic/#disc-brake-system-drum-brake-system__disc-brake-calipers-pads) under REMOVAL & INSTALLATION. Drain fluid from caliper. Secure caliper in a vise. Place a block of wood between caliper and piston(s). (Scheme 28) Apply low air pressure to brake hose inlet. Air pressure forces piston(s) outward.
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 use wire brush in caliper bores. Clean all components with isopropyl alcohol and dry with compressed air.
2. Inspect caliper 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 NEW piston seal with clean brake fluid, and install in caliper bore groove. Lubricate caliper bore 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 29)and (Scheme 30). Position piston and boot directly over caliper 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 caliper bore. DO NOT cock or jam piston in caliper bore. If necessary, use a "C" clamp and a block of wood to bottom piston in caliper bore.

Scheme 28

Scheme 29

1. Remove master cylinder. Clean outside of master cylinder. Remove filler cap and diaphragm. Drain any remaining fluid from cylinder. On dual master cylinder, remove stop bolt from bottom of master cylinder.
2. On all models, remove proportioning valve (if equipped). Depress pinion, and remove snap ring from end of master cylinder bore. (Scheme 31)and (Scheme 32). 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.

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.

Scheme 30

Scheme 31

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 Super Duty Pickup rear disc brakes, 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 1" 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/i-1985-2013/remont/mechanical-hydraulic/#disc-brake-system-drum-brake-system__disc-brake-specifications) table. 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/i-1985-2013/remont/mechanical-hydraulic/#disc-brake-system-drum-brake-system__disc-brake-specifications) table. 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/i-1985-2013/remont/mechanical-hydraulic/#disc-brake-system-drum-brake-system__disc-brake-specifications) table.

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 table.

Scheme 32

1. To measure maximum allowable stock remaining for refinishing on inner rotor face, use Disc Rotor Surface Gauge & Ball (T71P-1102-A). see scheme 33 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 and return spring from cylinder. Remove bleeder screw. Inspect cylinder bore for damage.

If cylinder bore is lightly pitted or scratched, hone or replace as necessary. DO NOT hone cylinders more than .003" (.08 mm). Coat all parts with clean brake fluid. To assemble, reverse disassembly procedure. Clamp brake cylinder pistons against ends of cylinder.

DISC BRAKE SPECIFICATIONS

FRONT DISC BRAKE SPECIFICATIONS

REAR DISC BRAKE SPECIFICATIONS

DRUM BRAKE SPECIFICATIONS

Note. Maximum drum diameter is stamped on outside of brake drum.

DRUM BRAKE SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• BLEEDING SEQUENCE
• BLEEDING SEQUENCE
• DISC BRAKE CALIPERS & PADS
• TORQUE SPECIFICATIONS
• BLEEDING BRAKE SYSTEM
• BLEEDING HYDRO-BOOST UNIT
• DISC BRAKE SPECIFICATIONS