1996 Ford E Super Duty 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...

Accessing Diagnostic Trouble Codes

• Ensure ignition switch is in Run position with engine off.
• Locate black RABS II diagnostic connector. Disconnect two halves of connector (one side has an orange/black wire attached to it).
• Attach a jumper wire to the orange/black wire side of the connector. Momentarily ground the opposite end of jumper for 1-2 seconds.
• The "REAR ABS" lamp should start flashing a diagnostic trouble code.

Diagnostic Trouble Code Interpretation

• Diagnostic trouble codes consist of a number of short flashes and ends with one long flash. Count short and long flashes to o...

Operation

The rear anti-lock brake system (RABS II) monitors rear wheel speed through a rear axle mounted sensor. If a lockup condition begins to develop, the RABS II module will control hydraulic pressure to the rear brakes, inhibiting wheel lockup.

Component Locations

Refer to Figs. through for RABS II component locations.

System Self-Test

The RABS II module performs system tests during vehicle start-up and normal operation. The RABS II valve assembly, sensor and fluid level circuits are monit...

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...

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...

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 ...