1996 Ford E-350 Econoline Brake Service (ONLINE REPAIR MANUALS)

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...

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...

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...

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...

Use the ABS wiring circuits, Figs. through , to aid in performing a thorough visual inspection of ...

Accessing Diagnostic Trouble Codes

The ABS electronic control module is capable of performing on-board diagnostics using Rotunda SUPER STAR II Tester scan tool No. 007-00041A or NGS Tester scan tool No. 007-00500, or equivalent.

On Bronco models, if suitable electronic tester is not available, warning lamp diagnostic trouble codes may be accessed in the following manner:

• Locate test connector, labeled "ANTI-LOCK TEST," in engine compartment. With ignition switch in Off position, connect a jumper wire between pins E and B.
• Turn ignition switch to Run position.
• Remove jumper wire aft...