Service Procedure
1. Check and adjust brake pad clearances and caliper knuckle clearances as follows:
a. Remove the pins from the caliper/knuckle.
Figure 1:
b. While holding the caliper in place against the bottom pin rails, Figure 1, measure the clearance between the caliper and the top pin rails. Clearance should be a minimum of .015".
c. If the clearance is insufficient, replace the knuckle.
NOTE: CHECK THE CLEARANCE ON THE NEW KNUCKLE BEFORE INSTALLATION.
d. After measuring the caliper/knuckle for proper clearances, remove both calipers and inner pad assemblies.
e. Remove the anti-rattle clip from the inner pad.
Figure 2:
Figure 3:
f. Reinstall the pad and check the side and end clearances with a feeler gauge. (See Figure 2 for clearance dimensions.)
g. If the pad clearances are within specification, install the anti-rattle clip on the lower pad tab, Figure 2. Refer to Service Procedure Step 2.
h. If the pad clearances are NOT WITHIN SPECIFICATION, file the shoe tabs.
WARNING: USE SAFETY GLASSES WHEN FILING SHOE TABS.
^ File material, removing equal amounts from both sides or ends. (See Figure 3.)
CAUTION: DO NOT GRIND. IT IS POSSIBLE TO REMOVE TOO MUCH MATERIAL WHEN GRINDING SHOES.
^ Check the tab clearances and install anti-rattle clip on the lower pad tab, Figure 2.
2. Apply a light coat of lubricant (D7AZ-19590-A) to the knuckle top and bottom pad groove and caliper rails.
CAUTION: MAKE SURE THE LUBRICANT DOES NOT GET ON THE ROTORS, LININGS, OR ON THE CALIPER PISTON BOOTS.
NOTE: FOR BRONCOS BUILT AFTER FEBRUARY 1990, THE RIGHT HAND RADIUS ARM PIVOT BRACKET IS BOLTED ON. REFER TO STEP 4. FOR ALL VEHICLES BUILT PRIOR TO FEBRUARY 1990, USE STEP 3.
3. Replace the right side radius arm bracket fasteners (Vehicles built prior to February 1990. This does not apply to F-350 4X4 or F-250 4X4 because no radius arms are used).
NOTE: THE SPECIFIED FASTENERS AND TORQUE REQUIREMENTS MUST BE USED. SEE FIGURE 4 FOR A DESCRIPTION OF PARTS CONTAINED IN THE RIGHT SIDE RADIUS ARM BRACKET KIT (E8TZ-3L095-A). REPLACE ONE RIVET AT A TIME TO MAINTAIN BRACKET LOCATION.
Figure 4:
a. Start with rivet number one (1). Drill an 1/8" hole through the middle of the rivet. See Figure 4.
b. Drill the same hole with an 11/32" drill.
c. Use an air chisel to remove the rivet head.
d. Drive the rivet out with a punch.
e. Line ream the rivet hole in the frame web to a 1/2" diameter. See Figure 4, reference rivet # 1.
Figure 5:
f. Install a 1/2" Grade 8 bolt. The bolt head must be on the inboard side of the frame. Install a 1/2" hardened washer on the outside of the bracket. Install the nut and tighten to 105 lb.ft. (142 N-m). See Figure 5.
g. Remove the number two (2) rivet using Steps a through d.
h. Line ream the number two (2) rivet hole on the frame flange to a 9/16" diameter, see Figure 4.
i. Install a 9/16" Grade 8 bolt. The bolt head must be on the inboard side of the frame flange. Install a 9/16" hardened washer on the outboard side of the bracket. Install the nut and tighten to 140 lb.ft. (190 N-m).
j. Repeat steps h and i for the number three
(3) rivet.
NOTE: MAKE SURE THE TORQUE SPECIFICATIONS ARE FOLLOWED.
CAUTION: STEP 4 APPLIES ONLY TO BRONCO VEHICLES BUILT AFTER FEBRUARY 1990. THE ATTACHMENT HARDWARE (NUTS AND BOLTS) USED IN THE SERVICE REPAIR AND PRODUCTION ARE DIFFERENT AND THE TORQUE SPECIFICATIONS ARE DIFFERENT. DO NOT APPLY STEP 4 ON BRONCOS BUILT BEFORE FEBRUARY 1990.
4. Check the torque on the nuts securing the right hand radius arm pivot bracket.
a. Check and adjust, if required, the torque of the nuts securing the right hand radius arm pivot bracket to the frame flange. The correct torque is 75 lb.ft. (100 N-m).
b. Check and adjust, if necessary, the torque of the nuts securing the right hand radius arm pivot bracket to the frame web (side rail). The correct torque is 110 lb.ft. (150 N-m).