1991 Ford E-150 Econoline Brake Service (ONLINE REPAIR MANUALS)

Make sure booster rubber reaction disc is properly installed as shown in Fig. , if the master cylinder pushrod is removed or accidentally pulled out. A dislodged disc may cause excessive pedal travel and extreme operation sensitivity. The disc is black compared to the silver colored valve plunger that will be exposed after pushrod and front seal are removed. The booster unit is serviced as an assembly and must be replaced if the reaction disc cannot be properly installed and aligned, or if it cannot be located within the unit itself.

• Disconnect battery ground cable.
• Disconn...

SERVICE BRAKE

The rear brake shoes, Figs. and , adjust automatically when the vehicle is driven forward or reverse and the brakes are applied sharply several times. Manual adjustment is required only when brake shoes are replaced. When adjusting rear brakes, ensure that parking brake is properly adjusted and that equalizer is operating freely.

With Drums Removed

• With drums removed, clean areas where shoes contact backing plate, then apply suitable lubricant to these contact areas, ensuring that lubricant does not contaminate linings.
• Using suitable brake shoe adjusting gauge, ad...

• Remove caliper and linings.
• Drain brake fluid from caliper housing, then position housing in a vise.
• Pad area between piston(s) and caliper bridge, then apply compressed air to caliper fluid port to remove piston(s). If piston is seized and cannot be forced from caliper, tap lightly around cylinder bore area while applying air pressure. Use caution when applying air pressure, as piston(s) may develop considerable force from pressure build-up.
• Remove and discard molded rubber boot(s) and square cut seal(s) from caliper assembly.
• Thoroughly clean piston(s) and caliper assembly using ...

The hydra-boost power brake booster is serviced as a unit.

REMOVAL

• With engine off, depress brake pedal several times to discharge the accumulator.
• Remove master cylinder from brake booster and position up and out of the way. Do not apply booster with master cylinder removed.
• Disconnect three hydraulic lines from booster, then disconnect input pushrod from brake pedal assembly, Fig. .
• Remove booster mounting nuts, then remove booster from vehicle. Do not carry booster by the accumulator and be careful not to drop booster on the accumulator. The snap ring on the accumulator shou...

• Remove caliper and linings.
• Drain brake fluid from caliper housing, then position housing in a vise.
• Pad area between piston(s) and caliper bridge, then apply compressed air to caliper fluid port to remove piston(s). If piston is seized and cannot be forced from caliper, tap lightly around cylinder bore area while applying air pressure. Use caution when applying air pressure, as piston(s) may develop considerable force from pressure build-up.
• Remove and discard molded rubber boot(s) and square cut seal(s) from caliper assembly.
• Thoroughly clean piston(s) and caliper assembly using ...

The hydra-boost power brake booster is serviced as a unit.

REMOVAL

• With engine off, depress brake pedal several times to discharge the accumulator.
• Remove master cylinder from brake booster and position up and out of the way. Do not apply booster with master cylinder removed.
• Disconnect three hydraulic lines from booster, then disconnect input pushrod from brake pedal assembly, Fig. .
• Remove booster mounting nuts, then remove booster from vehicle. Do not carry booster by the accumulator and be careful not to drop booster on the accumulator. The snap ring on the accumulator shou...