1992 Ford Explorer Brake Service (ONLINE REPAIR MANUALS)

Aerostar, Explorer & Ranger

These models use a pin sliding caliper type system, Fig. , in which the caliper slides on two pins attached to the spindle assembly.

Bronco, E-150 & F-150

These models use the LD (Light Duty) pin rail sliding caliper type system, Fig. , in which the single piston caliper slides on two pins attaching the caliper to the spindle assembly.

E-250-350, F-250-350 & F-Super Duty, Front

These models use the HD (Heavy Duty) pin rail sliding caliper type system, Fig. ,...

The Hydro-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 the booster from vehicle. Do not carry booster by accumulator and be careful not to drop booster on accumulator. Snap ring on accumulator should be checked fo...

Master Cylinder

The master cylinder consists primarily of a hydraulic cylinder, primary and secondary hydraulic pistons and a single or dual chamber fluid reservoir. The front brakes are connected to the primary outlet port(s) and are actuated by the primary piston assembly. The rear brakes are connected to the secondary outlet port and are actuated by the secondary piston assembly.

Hydraulic Control Valves

Combination Valve

This multi-function hydraulic control unit consists primarily of a pressure differential valve, brake lamp warning switch and a proportioning valve. A pressure diff...

This brake booster is a hydraulically operated booster, receiving its power from the power steering system, Fig. . The power steering pump provides fluid pressure to operate both the brake booster and the power steering gear. This fluid pressure provides a variable power assist that is regulated by brake pedal applic...

Brake Drums

Any time brake drums are removed for brake service, braking surface diameter should be checked with a suitable micrometer at several points to determine if they are within the safe oversize limit stamped on the brake drum outer surface. If braking surface diameter exceeds specifications, the drum must be replaced. If braking surface diameter is within specifications, drums should be cleaned and inspected for cracks, scores, deep grooves, taper, out of round and heat spotting. If drums are cracked or heat spotted, they must be replaced.

Minor scores should be removed with sa...

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...