1994 Ford F-250 Pickup Brake Service (ONLINE REPAIR MANUALS)

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...

Aerostar, Explorer & Ranger

• Remove caliper as described under "Caliper Service," leaving brake hose connected.
• Secure caliper with wire so that caliper is not hanging with weight on brake hose.
• Compress anti-rattle clip, then remove inner pad from caliper.
• Press each ear of outer pad away from caliper, slide torque buttons out of retention notches and slide pad off caliper.
• Reverse procedure to install, noting the following:
• Use an eight inch C-clamp and a worn inner pad or block of wood to bottom out caliper piston in bore.
• Install new anti-rattle clip on lower end of inner pad.
• Refill...

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 ...

Normal Hydro-Boost units will produce certain noises that current technology cannot correct. These noises occur when brake pedal is manipulated in a manner not associated with everyday braking habits. Normal operating noise can be a hissing, clunk, click or a chatter.

If above normal pedal efforts are applied, the Hydro-Boost unit will emit hissing noises. These noises will be particularly noticeable with the vehicle motionless and will increase in intensity as pedal efforts increase and system operating temperatures increase. Loud hissing noises at or below normal pedal effo...

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 for asbesto...