1996 Ford Explorer Brake Service (ONLINE REPAIR MANUALS)

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We have info for following modifications of 1996 Ford Explorer

  • 1996 Ford Explorer 4.0 V6 GAS, CID:245, Fuel Injection, Aspiration:245, Engine VIN:, Desg:X
  • 1996 Ford Explorer 5.0 V8 GAS, CID:302, Fuel Injection, Aspiration:302, Engine VIN:, Desg:P

BRAKE SERVICE PROCEDURES FOR 1996 Ford Explorer AUTOMOBILES

Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 1996 Ford Explorer cars and light trucks from 1990+.

Hydraulic Brake Systems -> Component Replacement -> 1992-94 -> 1995-96 -> Aerostar -> Bronco, E-Series & F-Series -> Master Cylinder -> Ranger & Explorer -> Villager -> Windstar
Vehicle: 1996 Ford Explorer 4.0 V6 GAS

Master Cylinder

Aerostar
1992-94
  • Disconnect brake warning lamp electrical connector from master cylinder.
  • Disconnect hydraulic lines from master cylinder, then remove master cylinder to brake booster nuts and master cylinder.
  • Before installing cylinder, check distance from outer end of master cylinder pushrod to front face of booster assembly using suitable gauge block, Fig. . Pushrod length should be .980-.995 inch. Turn pushrod adjusting screw inward or outward until specified length is achieved.
  • Install master cylinder and nuts, then connect hydraulic lines and brake warning ...

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BRAKE SERVICE PROCEDURES FOR 1996 Ford Explorer AUTOMOBILES

Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 1996 Ford Explorer cars and light trucks from 1990+.

Power Brake Units -> Bendix Hydro-Boost Brake Booster -> Power Brake Unit Service -> Installation -> Removal
Vehicle: 1996 Ford Explorer 5.0 V8 GAS

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...

CLICK HERE TO GET FULL ACCESS TO 1996 Ford Explorer BRAKE SERVICE PROCEDURES

BRAKE SERVICE PROCEDURES FOR 1996 Ford Explorer AUTOMOBILES

Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 1996 Ford Explorer cars and light trucks from 1990+.

Disc Brakes -> Brake System Bleed
Vehicle: 1996 Ford Explorer 4.0 V6 GAS

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.

  • Loosen master cylinder to hydraulic line nuts and wrap shop cloths around tubing below fitting to absorb escaping brake fluid.
  • Depress brake pedal slowly forcing air trapped in master cylinder out at fitting.
  • Hold pedal down and tighten fittings, then release brake pedal. Releasing brake pedal before fittings are tightened will allow air to en...

CLICK HERE TO GET FULL ACCESS TO 1996 Ford Explorer BRAKE SERVICE PROCEDURES

BRAKE SERVICE PROCEDURES FOR 1996 Ford Explorer AUTOMOBILES

Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 1996 Ford Explorer cars and light trucks from 1990+.

Drum Brakes -> Aerostar, Bronco, Explorer, E-150, F-150 & Ranger -> Brake Service -> Explorer -> Installation -> Parking Brake w/Rear Disc -> Removal
Vehicle: 1996 Ford Explorer 4.0 V6 GAS

Removal

  • Raise and support vehicle, then remove wheel and tire assembly.
  • Remove brake drum. If brake drum will not come off, remove rubber plug from adjuster hole and insert a screwdriver and brake adjustment tool No. D81L-1103-C, or equivalent, to disengage brake shoe adjusting lever and loosen brake adjuster screw .
  • Inspect wheel cylinders for signs of leakage. If evidence of leakage is present, service cylinders as necessary.
  • Install brake cylinder clamp tool No. D 81L-1103-B, or equivalent, over ends of wheel cylinder, then contract brake shoes as follows:
    • Disengage adjusting lever ...

CLICK HERE TO GET FULL ACCESS TO 1996 Ford Explorer BRAKE SERVICE PROCEDURES

BRAKE SERVICE PROCEDURES FOR 1996 Ford Explorer AUTOMOBILES

Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 1996 Ford Explorer cars and light trucks from 1990+.

Disc Brakes -> Precautions -> Aerostar, Explorer & Ranger -> Brake Bleeding -> Brake Disc Service -> Brake Linings -> Brake Roughness -> Caliper Inspection -> General Precautions
Vehicle: 1996 Ford Explorer 5.0 V8 GAS

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 ...

CLICK HERE TO GET FULL ACCESS TO 1996 Ford Explorer BRAKE SERVICE PROCEDURES

BRAKE SERVICE PROCEDURES FOR 1996 Ford Explorer AUTOMOBILES

Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 1996 Ford Explorer cars and light trucks from 1990+.

Power Brake Units -> Bendix Hydro-Boost Brake Booster -> Diagnosis & Testing -> 1992 -> Hydro-Boost Leak Test -> Performance Check -> Reserve Retention Check
Vehicle: 1996 Ford Explorer 5.0 V8 GAS

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...

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