1992 Ford E-150 Econoline Brake Service (ONLINE REPAIR MANUALS)

Except Windstar

Bleed primary and secondary hydraulic brake systems separately, bleeding the longest line first on each system. Do not allow reservoir to run dry during bleeding operation. Never reuse fluid that has been drained from the hydraulic system. Ensure proper bleed sequence is followed.

On Aerostar, Bronco, E-Series, Explorer, F-Series and Ranger models, the bleed order is right rear, left rear, right front, left front.

On Villager models, the bleed order is left front, right front, left rear, right rear.

• Loosen master cylinder to hydraulic line nuts and wrap sho...

When working on or around brake assemblies, care must be taken to prevent breathing asbestos dust, as many manufacturers incorporate asbestos fibers in the production of brake linings. During routine service operations, precautions should be taken to minimize exposure. Do not sand or grind brake linings unless suitable local exhaust ventilation equipment is used to prevent excessive asbestos exposure.

• Wear a suitable respirator approved fo...

Brake Linings

Remove both front wheels and inspect the brake discs, calipers and linings. (Wheel bearings should be inspected at this time and repacked if necessary).

Do not get any oil or grease on the linings. It is recommended that both front wheel sets be replaced whenever a respective shoe and lining is worn or damaged. Inspect and, if necessary, replace rear brake linings also.

If the caliper is cracked or fluid leakage through the casting is evident, it must be replaced as a unit.

Brake Roughness

The most common cause of brake chatter on disc brakes is a variation in thickness of ...

Replace

Aerostar, Explorer & Ranger

• Remove and discard a portion of brake fluid from master cylinder.
• Raise and support vehicle, then remove wheel and tire assembly.
• Use an eight inch C-clamp to move piston back into its bore as follows:
• Place head of C-clamp against caliper and screw end of C-clamp against outer pad below spring clip.
• Tighten C-clamp until torque buttons just clear caliper (approximately 1/8 inch). Remove C-clamp.
• Clean excess dirt from around pin tabs, then use caliper pin remover tool No. D89T-2196-A or equivalent and light hammer to drive caliper pin from caliper a...

Parking Brake

Explorer

Rear Disc

• Remove rear disc brake rotor as outlined in "Rotor, Replace".
• Using tool No. D81L-1103-A or equivalent, brake adjustment gauge or equivalent, measure inside diameter of parking brake drum, Fig. .
• Using parking brake adjuster screw, adjust parking brake shoe to .020 inch (.508 mm) less than drum measurement, Fig. .
• Reverse procedure to install.

Transmission Mounted

F-Super Duty, Rear

• Place transmission in neutral position and release parking brake, t...

Bronco, E-Series & F-Series

Ensure booster rubber reaction disc is properly installed as shown, Fig. . 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 the pushrod and front seal are removed.

1992-94

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.
• Disconnect stop lamp switch electrical con...