# Disc Brakes

## Brake Pads

### REMOVAL & INSTALLATION

#### Front Pads

Caliper mounting bolt locations

Click to enlarge

Loosen the caliper mounting bolts

The pads can be accessed by removing the lower caliper bolt and rotating the caliper up as shown

Support the caliper with a piece of mechanic's wire or other suitable device

Remove the outer and ...

... inner brake pads from the caliper bracket

A special tool from Lisle®, shown here, is available to compress the caliper piston

If the special tool is not available, a large C-clamp works well

Thoroughly clean the caliper brackets before installing the new pads

Remove the caliper slides and ...

... thoroughly clean the slides

Lubricate the caliper slides before reinstalling them into the caliper bracket

Make sure that the caliper tension spring is installed into the caliper before installing the caliper

Before installing the brake pads, it is recommended that you apply a suitable anti-squeal lubricant to the pads and ...

... spread the lubricant evenly over the backing of the brake pads

CAUTION
Older brake pads or shoes may contain asbestos, which has been determined to be cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.

1. To avoid overflowing of the master cylinder when the caliper pistons are pressed into the caliper cylinder bores, siphon or dip some brake fluid out of the larger reservoir.

CAUTION
Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance.

2. Raise and support the vehicle on jackstands.
3. Remove the wheels.
4. Place an suitable C-clamp on the caliper and, with the clamp bearing on the outer pad, tighten the clamp to bottom the caliper pistons in the cylinder bores. Remove the C-clamp.
5. Loosen and remove the caliper retaining bolts.
6. Lift the caliper off of the rotor.

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

7. Remove the brake pads and anti-rattle spring.

To install:

8. Thoroughly clean the areas of the caliper and spindle assembly which contact each other during the sliding action of the caliper.
9. Place a new anti-rattle clip on the lower end of the inboard shoe. Make sure that the tabs on the clip are positioned correctly and the loop-type spring is away from the rotor.
10. Place the lower end of the inner brake pad in the spindle assembly pad abutment, against the anti-rattle clip, and slide the upper end of the pad into position. Be sure that the clip is still in position.
11. Check and make sure that the caliper piston is fully bottomed in the cylinder bore. Use a large C-clamp to bottom the piston, if necessary.
12. Position the outer brake pad on the caliper, and press the pad tabs into place with your fingers. If the pad cannot be pressed into place by hand, use a C-clamp. Be careful not to damage the lining with the clamp. Bend the tabs to prevent rattling.
13. Position the caliper on the spindle assembly. Lightly lubricate the caliper sliding pins with a suitable grease.
14. Position the caliper pins into the caliper anchor plate.
15. Tighten the caliper pins to 16-30 ft. lbs. (22-40 Nm) on 19997-98 F-250HD, F-350 and F-Super duty models. Tighten the caliper pins to 21-26 ft. lbs. (28-36 Nm) on the F-150, F-250, Expedition and Navigator. Tighten the caliper pins to 42 ft. lbs. (56 Nm) on the 1999-00 F-250SD, F-350 and F-Super Duty models.
16. Install the wheels.
17. Lower the vehicle.
18. Pump the brake pedal a few times to build adequate pressure in the brake system and check the fluid level in the master cylinder.

#### Rear Pads

##### 1997-98 F-SUPER DUTY MODELS

Brake caliper assembly—1997-98 F-Super Duty models

Click to enlarge

CAUTION
Older brake pads or shoes may contain asbestos, which has been determined to be cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.

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

1. To avoid overflowing of the master cylinder when the caliper pistons are pressed into the caliper cylinder bores, siphon or dip some brake fluid out of the larger reservoir.
2. Raise and support the rear end on jackstands.
3. Remove the wheels.
4. Place a suitable C-clamp on the caliper and tighten the clamp to bottom the caliper pistons in the cylinder bores. Remove the C-clamp.
5. Clean the excess dirt from around the caliper pin tabs.
6. Drive the upper caliper pin inward until the tabs on the pin touch the caliper support.
7. Insert a small prybar into the slot provided behind the pin tabs on the inboard side of the pin.
8. Using needlenose pliers, compress the outboard end of the pin while, at the same time, prying with the prybar until the tabs slip into the groove in the caliper support.
9. Place the end of a 7/16 in. (11mm) punch against the end of the caliper pin and drive the pin out of the caliper slide groove.
10. Repeat this procedure for the lower pin.
11. Lift the caliper off of the rotor.
12. Remove the brake pads and anti-rattle spring.

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

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

To install:

14. Place a new anti-rattle clip on the lower end of the inboard shoe. Make sure that the tabs on the clip are positioned correctly and the loop-type spring is away from the rotor.
15. Place the lower end of the inner brake pad in the caliper support assembly pad abutment, against the anti-rattle clip, and slide the upper end of the pad into position. Be sure that the clip is still in position.
16. Check and make sure that the caliper pistons are fully bottomed in the cylinder bores. Use a large C-clamp to bottom the pistons, if necessary.
17. Position the outer brake pad on the caliper, and press the pad tabs into place with your fingers. If the pad cannot be pressed into place by hand, use a C-clamp. Be careful not to damage the lining with the clamp. Bend the tabs to prevent rattling.
18. Position the caliper on the caliper support. Lightly lubricate the caliper sliding grooves with caliper pin grease.
19. Position the a new upper pin with the retention tabs next to the support groove.

Don't use the bolt and nut with the new pin.

20. Carefully drive the pin, at the outboard end, inward until the tabs contact the caliper support face.
21. Repeat the procedure for the lower pin.

WARNING
Don't drive the pins in too far, or it will be necessary to drive them back out until the tabs snap into place. The tabs on each end of the pin MUST be free to catch on the support sides!

22. Install the wheels.
23. Lower the vehicle.
24. Pump the brake pedal a few times to build adequate pressure in the brake system and check the fluid level in the master cylinder.

##### EXCEPT 1997-98 F-SUPER DUTY MODELS

CAUTION
Older brake pads or shoes may contain asbestos, which has been determined to be cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.

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

1. Remove the rear brake caliper from the rear hub without disconnecting the brake hose.

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

2. Remove the brake pads and anti-rattle spring.
3. Thoroughly clean the areas of the caliper and caliper support assembly which contact each other during the sliding action of the caliper.

To install:

4. Retract the caliper piston into the caliper using a suitable tool.
5. Position the brake shoes and anti-rattle clips on the disc brake caliper support bracket.
6. Install the rear disc brake caliper onto the rear support bracket. Tighten the caliper retaining pins on the F-150, F-250, Expedition and Navigator to 20 ft. lbs. ( 27 Nm). Tighten the caliper retaining bolts on the 1999-00 F-Super Duty models to 27 ft. lbs. (36 Nm.)
7. Bleed the brake system.
8. Clean the wheel hub mounting surface.
9. Install the front wheels and snug the lug nuts to fully seat the wheel against the hub.
10. Lower the vehicle until some of the vehicle's weight rests on the front tires, then tighten the lug nuts to 83-112 ft. lbs. (113-153 Nm).
11. Lower the vehicle completely.
12. Pump the brake pedal a few times to build adequate pressure in the brake system and check the fluid level in the master cylinder.

### INSPECTION

A gauge that measures in 1/32's of an inch is available to measure brake pad thickness

A ruler can also be used. Make sure to measure the pads in several places since pads can wear unevenly

CAUTION
Older brake pads or shoes may contain asbestos, which has been determined to be cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.

Inspect the brake pads for wear using a ruler, Vernier caliper or other suitable device. Compare measurements to the brake specifications chart. If the lining is thinner than specification or there is evidence of the lining being contaminated by brake fluid or oil, make the necessary repairs and replace all brake pad assemblies (a complete axle set).

## Brake Caliper

### REMOVAL & INSTALLATION

#### Front Caliper

Loosen the brake hose bolt and ...

... remove the brake hose from the caliper

Discard the copper washers and replace them

Plug the inlet port on the caliper

Caliper mounting bolt locations

Click to enlarge

Loosen the caliper mounting bolts

1. Raise and safely support the vehicle securely on jackstands.
2. Remove the front wheels.
3. Remove the front brake hose bolt, then remove the copper washers and plug the front brake hose.
4. Remove the 2 front disc brake caliper slide pins, then lift the caliper off of the front caliper anchor plate.

To install:

5. Install the front disc brake caliper onto the caliper anchor plate, then install the 2 slide pins. Tighten the slider pins/bolts to 16-30 ft. lbs. (22-40 Nm) on the 1997-98 F-250HD, F-350 and F-Super Duty models. Tighten the bolts to 21-26 ft. lbs. (28-36 Nm) on the F-150, F-250, Expedition and Navigator. Tighten the bolts to 42 ft. lbs. (56 Nm). On the 1999-00 F-Super Duty models.
6. Using new copper washers, attach the front brake hose to the brake caliper, then install and tighten the retaining bolt to 23-29 ft. lbs. (30-40 Nm).
7. Bleed the brake system.
8. Clean the wheel hub mounting surface.
9. Install the front wheels and snug the lug nuts to fully seat the wheel against the hub.
10. Lower the vehicle until some of the vehicle's weight rests on the front tires, then tighten the lug nuts to 83-112 ft. lbs. (113-153 Nm).
11. Lower the vehicle completely.
12. Make sure that the brakes are operating correctly.

#### Rear Caliper

##### 1997-98 F-SUPER DUTY

Brake caliper assembly—1997-98 F-Super Duty models

Click to enlarge

1. Remove sufficient brake fluid from the brake master cylinder reservoir to allow for pressing the caliper pistons into the bores. Discard the used brake fluid.
2. Raise and safely support the vehicle.
3. Remove the wheels.
4. Place a suitable C-clamp on the caliper, with he clamp frame on the disc brake caliper and the clamp screw on the outboard brake hoes and lining backing plate, then tighten the clamp to press the caliper pistons in the cylinder bores only enough to give removal clearance. Remove the C-clamp.
5. Remove the rear brake hose-to-caliper flow bolt and discard the used copper washers. Plug the brake hose so that contamination of the brake fluid does not occur.
6. Using the Caliper Pin Remover D89T-2196-A, or equivalent, drive the upper and lower caliper locking pins out.
7. Remove the disc brake caliper from the vehicle.

To install:

8. If necessary, install the brake shoe and anti-rattle clip.
9. Position the disc brake caliper in the support bracket.
10. Lubricate the caliper locking pins with Ford Silicone Dielectric Compound D7AZ-19A331-A or equivalent.
11. Drive the locking pins into the caliper/support bracket assembly until the tabs at each end of the pin snap into place.
12. Using new copper washers, attach the rear brake hose to the disc brake caliper. Tighten the rear brake hose-to-caliper flow bolt to 22-29 ft. lbs. (30-39 Nm).
13. Install the wheel, then lower the vehicle.

Check the brake fluid level in the brake master cylinder reservoir and maintain sufficient level to prevent air from entering the system.

14. Pump the brake pedal several times to drive the caliper pistons into contact with the brake shoe and lining.
15. Fill the brake master cylinder reservoir with new DOT 3 brake fluid.
16. Bleed the brake system and test the brakes for proper operation.

##### F-150, F-250, EXPEDITION, NAVIGATOR AND 1999-00 F-SUPER DUTY MODELS

WARNING
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during these operations.

1. Raise and support the vehicle.
2. Remove the wheel and tire assembly.

CAUTION
Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance.

3. Remove bolt and disconnect the rear wheel brake hose.
4. Remove the copper washers and plug the brake hose.

WARNING
Do not remove the guide pins or guide pin boots unless a problem is suspected. The guide pins are meant to be sealed for life and are not repairable. Use Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A for re-lubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in contamination and accelerated corrosion or wear of the caliper slide pin mechanism.

5. Remove the brake caliper bolts.
6. Lift the rear disc brake caliper off the rear disc brake caliper anchor plate.
7. Inspect the rear disc brake caliper for leaks.

To install:

When installed, the locator notch on the brake pads will be located at the upper end of the rear disc brake caliper.

8. Install the rear disc brake caliper.
9. Install the rear wheel brake hose.
10. Connect the brake hose and install and use new copper washers.
11. Tighten the brake hose bolt.
12. Bleed the disc brake caliper.

If equipped with air suspension, reactivate the system by turning on the air suspension switch.

13. Install the wheel and tire assembly.
14. Verify correct brake operation.

### OVERHAUL

Some vehicles may be equipped dual piston calipers. The procedure to overhaul the caliper is essentially the same with the exception of multiple pistons, O-rings and dust boots.

1. Remove the caliper from the vehicle and place on a clean workbench.

CAUTION
NEVER place your fingers in front of the pistons in an attempt to catch or protect the pistons when applying compressed air. This could result in personal injury!

Depending upon the vehicle, there are two different ways to remove the piston from the caliper. Refer to the brake pad replacement procedure to make sure you have the correct procedure for your vehicle.

2. The first method is as follows:
   1. Stuff a shop towel or a block of wood into the caliper to catch the piston.
   2. Remove the caliper piston using compressed air applied into the caliper inlet hole. Inspect the piston for scoring, nicks, corrosion and/or worn or damaged chrome plating. The piston must be replaced if any of these conditions are found.

For some types of calipers, use compressed air to drive the piston out of the caliper, but make sure to keep your fingers clear

Withdraw the piston from the caliper bore

3. For the second method, you must rotate the piston to retract it from the caliper.
4. If equipped, remove the anti-rattle clip.

On some vehicles, you must remove the anti-rattle clip

5. Use a prytool to remove the caliper boot, being careful not to scratch the housing bore.

Use a prytool to carefully pry around the edge of the boot ...

... then remove the boot from the caliper housing, taking care not to score or damage the bore

6. Remove the piston seals from the groove in the caliper bore.

Use extreme caution when removing the piston seal; DO NOT scratch the caliper bore

7. Carefully loosen the brake bleeder valve cap and valve from the caliper housing.
8. Inspect the caliper bores, pistons and mounting threads for scoring or excessive wear.
9. Use crocus cloth to polish out light corrosion from the piston and bore.
10. Clean all parts with denatured alcohol and dry with compressed air.

To assemble:

11. Lubricate and install the bleeder valve and cap.
12. Install the new seals into the caliper bore grooves, making sure they are not twisted.
13. Lubricate the piston bore.
14. Install the pistons and boots into the bores of the calipers and push to the bottom of the bores.
15. Use a suitable driving tool to seat the boots in the housing.

Use the proper size driving tool and a mallet to properly seal the boots in the caliper housing

16. Install the caliper in the vehicle.
17. Install the wheel and tire assembly, then carefully lower the vehicle.
18. Properly bleed the brake system.

There are tools, such as this Mighty-Vac, available to assist in proper brake system bleeding

## Brake Disc (Rotor)

### REMOVAL & INSTALLATION

#### 1997-98 F-250HD and F-350

##### 4 X 2 MODELS FRONT DISC

Brake rotor mounting—1997-98 F-250HD and F-350 4 X 2

Click to enlarge

1. Raise and safely support the vehicle.
2. Remove the wheel and tire assembly.
3. Remove the caliper assembly and support it on the frame with a piece of wire without disconnecting the brake fluid hose.
4. Remove the hub grease cap.
5. Remove the cotter pin.
6. Remove the retainer nut.
7. Remove the spindle nut.
8. Remove the outer bearing retainer washer and wheel bearing.
9. Remove the disc brake hub and rotor assembly.
10. Remove the bearing grease seal and the inner bearing.

To install:

11. If the brake rotor is being replaced, remove the protective coating from the new rotor. If the original rotor is being installed, ensure that the rotor braking surfaces are clean.
12. Thoroughly clean and inspect the front wheel bearings and the front disc brake hub and rotor.
13. Lubricate the front wheel bearings using premium long-life grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B.
14. Install the inner front wheel bearing.
15. Install a new wheel hub grease seal.
16. Place the hub and rotor assembly on the wheel spindle and install the outer wheel bearing.
17. Install the washer and spindle nut.
18. Adjust the wheel bearings.
19. Install the retainer nut, cotter pin and dust cap.
20. Install the caliper assembly.
21. Install the wheel and tire assembly.
22. Lower the vehicle.

##### 4 X 4 MODELS FRONT DISC

1. Raise and safely support the vehicle.
2. Remove the wheel and tire assembly.
3. Remove the caliper assembly and support it on the frame with a piece of wire without disconnecting the brake fluid hose.
4. Remove the manual or automatic locking hubs.
5. Remove the front disc brake hub and rotor.
6. Remove the wheel hub grease seal.
7. Remove the inner front wheel bearing.

To install:

8. If the brake rotor is being replaced, remove the protective coating from the new rotor. If the original rotor is being installed, ensure that the rotor braking surfaces are clean.
9. Thoroughly clean and inspect the front wheel bearings and the front disc brake hub and rotor.
10. Lubricate the front wheel bearings using premium long-life grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B.
11. Install the inner front wheel bearing.
12. Install a new wheel hub grease seal.
13. Place the hub and rotor assembly onto the spindle.
14. Install the hub assembly.
15. Install the caliper assembly.
16. Install the wheel and tire assembly.
17. Lower the vehicle.

#### 1997-98 F-Super Duty

##### FRONT

Brake rotor mounting—1997-98 F-Super-Duty

Click to enlarge

1. Raise and safely support the vehicle securely on jackstands.
2. Remove the brake caliper assembly.
3. Remove the front disc brake caliper anchor plate.
4. Remove the hub grease cap.
5. Remove the cotter pin.
6. Remove the spindle nut.
7. Remove the front wheel outer bearing retainer washer.
8. Remove the outer front wheel bearing.
9. Remove the hub grease cap gasket.
10. Remove the front disc brake hub and rotor.
11. Remove the wheel hub grease seal.
12. Remove the inner front wheel bearing.

To install:

13. If the brake rotor is being replaced, the hub is removed from the rotor. Remove the hub retaining bolts and remove the hub from the rotor. Install the hub onto the new rotor. Tighten the retaining bolts to 74-89 ft. lbs. (100-120 Nm).
14. Thoroughly clean and inspect the front wheel bearings and the front disc brake hub and rotor.
15. Lubricate the front wheel bearings using premium long-life grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B.
16. Install the inner front wheel bearing.
17. Install a new wheel hub grease seal.
18. Install the front disc brake hub and rotor.
19. Install the outer front wheel bearing.
20. Install the front wheel outer bearing retainer washer.
21. Install the spindle nut.
22. While rotating the front disc brake hub and rotor, tighten the spindle nut.
23. Loosen the spindle nut two turns.
24. Tighten the spindle nut while rotating the front disc brake hub and rotor.
25. Loosen the spindle nut.
26. Tighten the spindle nut while rotating the front disc brake hub and rotor.
27. Install the cotter pin.
28. Install the hub grease cap gasket and the hub grease cap.
29. Install the front disc brake caliper anchor plate.
30. Install the brake caliper.
31. Install the wheel and tire assembly.
32. Lower the vehicle.

##### REAR

F-Super Duty rear disc brake assembly

Click to enlarge

1. Raise and safely support the vehicle securely on jackstands.
2. Remove the wheel and tire assembly.
3. Remove the axle shaft retaining bolts and remove the axle shaft.
4. Using a suitable hub socket, loosen and remove the hub socket.
5. Remove the outer wheel bearing.
6. Remove the hub and rotor.
7. Remove the rotor-to-hub bolts and separate the hub and rear disc brake rotor.

To install:

8. The installation is the reverse of the removal.

#### F-150, F-250, Expedition and Navigator

##### FRONT

Remove the two caliper anchor plate retaining bolts and ...

... remove the caliper anchor plate

Lift the rotor off of the hub assembly—4 X 4 models only

1. Raise and safely support the vehicle.
2. Remove the wheel and tire assembly.
3. Remove 2 caliper slide pins and lift the caliper off the anchor plate.
4. Secure the caliper out of the way without damaging the brake hose.
5. Remove the disc brake pads and anti-rattle clips.
6. Remove 2 anchor plate retaining bolts and remove the anchor plate.
7. On 4x4 vehicles, remove the rotor from the hub assembly by pulling it off the hub studs. If additional force is required to remove the rotor, apply rust penetrating fluid on the front and rear rotor/hub mating surfaces and then strike the rotor between the studs with a plastic hammer. If this does not work, attach a 3-jaw puller and remove the rotor.
8. On 4x2 vehicles:
   1. Remove the hub grease cap.
   2. Remove the cotter pin.
   3. Remove the retainer nut.
   4. Remove the spindle nut.
   5. Remove the outer bearing retainer washer and wheel bearing.
   6. Remove the disc brake hub and rotor assembly.

If excessive force must be used to remove the rotor, it should be checked for lateral run-out before installation.

9. Check the brake rotor for scoring and/or wear. Machine or replace, as necessary. If machining, observe the minimum thickness specification stamped on the rotor.

To install:

10. If the brake rotor is being replaced, remove the protective coating from the new rotor. If the original rotor is being installed, ensure that the rotor braking surfaces are clean.
11. On 4x4 vehicles, apply a small amount of silicone dielectric compound to the pilot diameter of the disc brake rotor and install the rotor on the hub assembly.
12. On 4x2 vehicles:
    1. Install the inner wheel bearing with a new grease seal.
    2. Place the hub and rotor assembly on the wheel spindle and install the outer wheel bearing.
    3. Install the washer and spindle nut.
    4. Adjust the wheel bearings.
    5. Install the retainer nut, cotter pin and dust cap.
13. Place the anchor plate and install 2 retaining bolts. Tighten the bolts to 125-168 ft. lbs. (170-230 Nm).
14. Install the brake pad anti-rattle clips and install the disc brake pads.
15. Slide the disc brake caliper into position. Install and tighten the caliper sliding pins to 21-26 ft. lbs. (28-36 Nm).
16. Install the wheel and tire assembly. Tighten the lug nuts to 83-112 ft. lbs. (113-153 Nm).
17. Lower the vehicle.
18. Pump the brake pedal several times to position the brake pads prior to moving the vehicle.
19. Road test the vehicle and check for proper brake system operation.

##### REAR

When removing the rear disc brake caliper in this procedure, it is not necessary to disconnect the rear wheel brake hose.

1. Remove the rear disc brake caliper.

If the brake disc binds on the parking brake shoe and lining, remove the adjustment hole access plug and contract the parking brake shoe and lining.

2. Remove the press-on keeper nuts, if so equipped.
3. Remove the brake disc.
4. Inspect the brake disc. Replace the brake disc if necessary.

To install:

5. Install the brake disc.
6. Install the rear disc brake caliper.
7. Install the wheel and tire assembly.
8. Lower the vehicle.

#### 1999-00 F-250SD and F-350 4x2

##### FRONT

Brake rotor mounting—1999-00 F-250SD and F-350 4 X 2

1. Raise and safely support the vehicle securely on jackstands.
2. Remove the wheel and tire assembly.
3. Remove the front disc brake caliper anchor plate.
4. Remove the hub grease cap.
5. Remove the cotter pin.
6. Remove the nut retainer.
7. Remove the spindle nut.
8. Remove the front wheel outer bearing retainer washer.
9. Remove the outer front wheel bearing.
10. Remove the front disc brake hub and rotor.
11. Remove the wheel hub grease seal.
12. Remove the inner front wheel bearing.

To install:

13. Thoroughly clean and inspect the front wheel bearings and the front disc brake hub and rotor.
14. Lubricate the front wheel bearings using premium long-life grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B.
15. Install the inner front wheel bearing.
16. Install a new wheel hub grease seal.
17. Install the front disc brake hub and rotor.
18. Install the outer front wheel bearing.
19. Install the front wheel outer bearing retainer washer.
20. Install the spindle nut.
21. While rotating the front disc brake hub and rotor, tighten the spindle nut.
22. Loosen the spindle nut two turns.
23. Tighten the spindle nut while rotating the front disc brake hub and rotor.
24. Loosen the spindle nut.
25. Tighten the spindle nut while rotating the front disc brake hub and rotor.
26. Install the following components:

- Install the nut retainer.
- Install the cotter pin.
- Install the hub grease cap.

27. Install the front disc brake caliper anchor plate.
28. Install the wheel and tire assembly.
29. Lower the vehicle.

#### 1999-00 F-250 and F-350 4x4

##### FRONT

Brake rotor mounting—1999-00 F-250SD and F-350 4 X 4 with single rear wheels

Brake rotor mounting—1999-00 F-250SD and F-350 4 X 4 with dual rear wheels

1. Raise and safely support the vehicle securely on jackstands.
2. Remove the wheel and tire assembly.
3. Remove the front brake caliper.
4. Remove the front disc brake caliper anchor plate.
5. On single rear wheel (SRW) vehicles, remove the rotor.
6. On dual rear wheel (DRW) vehicles:
   1. Remove the eight hub plate nuts.
   2. Remove the hub plate.
   3. Remove the rotor.

To install:

7. Position the front disc brake rotor to the wheel hub. Make sure the wheel hub and the front disc brake rotor braking and mounting surfaces are clean.
8. On dual rear wheel (DRW) vehicles:
   1. Install the front wheel hub plate and nuts. Tighten the hub plate nuts to 130 ft. lbs. (176 Nm).
9. Install the front disc brake caliper anchor plate.
10. Install the brake caliper.
11. Install the wheel and tire assembly.
12. Lower the vehicle.

#### 1999-00 F-Super Duty and Motorhome Chassis

##### FRONT

1. Raise and safely support the vehicle securely on jackstands.
2. Remove the brake caliper assembly.
3. Remove the front disc brake caliper anchor plate.
4. Remove the hub grease cap screws.
5. Remove the hub grease cap.
6. Remove the cotter pin.
7. Remove the spindle nut.
8. Remove the front wheel outer bearing retainer washer.
9. Remove the outer front wheel bearing.
10. Remove the hub grease cap gasket.
11. Remove the front disc brake hub and rotor.
12. Remove the wheel hub grease seal.
13. Remove the inner front wheel bearing.

To install:

14. Thoroughly clean and inspect the front wheel bearings and the front disc brake hub and rotor.
15. Lubricate the front wheel bearings using premium long-life grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B.
16. Install the inner front wheel bearing.
17. Install a new wheel hub grease seal.
18. Install the front disc brake hub and rotor.
19. Install the outer front wheel bearing.
20. Install the front wheel outer bearing retainer washer.
21. Install the spindle nut.
22. While rotating the front disc brake hub and rotor, tighten the spindle nut.
23. Loosen the spindle nut two turns.
24. Tighten the spindle nut while rotating the front disc brake hub and rotor.
25. Loosen the spindle nut.
26. Tighten the spindle nut while rotating the front disc brake hub and rotor.
27. Install the cotter pin.
28. Install the hub grease cap gasket and the hub grease cap.
29. Install the hub grease cap screws.
30. Install the front disc brake caliper anchor plate.
31. Install the brake caliper.
32. Install the wheel and tire assembly.
33. Lower the vehicle.

#### 1999-00 F-250SD, F-350 and F-Super Duty

##### REAR

1. Raise and safely support the vehicle securely on jackstands.
2. Remove the wheel and tire assembly.
3. Remove the axle shaft retaining bolts and remove the axle shaft.
4. Using a suitable hub socket, loosen and remove the hub socket.
5. Remove the outer wheel bearing.
6. Remove the hub and rotor.
7. Remove the rotor-to-hub bolts and separate the hub and rear disc brake rotor.

To install:

8. The installation is the reverse of the removal.

### INSPECTION

Check brake rotor thickness in several places around the rotor using a Vernier caliper

Rotor thickness should be measured any time a brake inspection is done. Rotor thickness can be measured using a brake rotor micrometer or Vernier caliper. Measure the rotor thickness in several places around the rotor. Compare the thickness to the specifications chart found at the end of this section.

The run-out of the brake rotor should be checked any time a vibration during braking occurs. Excessive run-out can be caused by a build-up of rust scale or other particles on the rotor or hub surfaces. Remove the rotor and thoroughly clean the hub and rotor-to-hub mounting surface on the back of the rotor. Mount a dial indicator to a suspension member and zero the indicator stylus on the face of the rotor. Rotate the rotor 360 degrees by hand and record the run-out.

Compare measurements to the brake specifications chart. If the thickness and run-out do not meet specifications, replace the rotor.