1996 Ford E Super Duty Brake Service (ONLINE REPAIR MANUALS)

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...

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...

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...

The single and tandem vacuum boosters are self contained vacuum hydraulic power braking units. These are vacuum suspended units that use vacuum and atmospheric pressure for their power.

On gasoline engine vehicles, vacuum is supplied through a fitting in the intake manifold. On diesel engine vehicles, vacuum is supplied through a vacuum pump.

The three basic elements of the booster are the vacuum power chamber, mechanically actuated booster check va...

Pushrod

Bronco, E-Series & F-Series

To check adjustment of pushrod, fabricate a gauge and position it against the master cylinder mounting surface as shown in Fig. . Adjust pushrod screw by turning it until the end just touches inner edge of slot in gauge.

Windstar

• Without disconnecting brake tubes...

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...