Disc Brake System: Service and Repair

Brake Pads





Material

Removal

WARNING: Use of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury.

WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury.

CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.

1. Check the brake fluid level in the brake master cylinder reservoir.
^ If required, remove the fluid until the brake master cylinder reservoir is half full.
2. With the vehicle in NEUTRAL, position it on a hoist.





3. CAUTION: Do not pry in the caliper sight hole to retract the pistons, as this can damage the pistons and boots.

CAUTION: Do not allow the brake caliper to hang from the brake caliper flexible hose. Use a suitable tool to support the brake caliper.

Remove the 2 brake caliper bolts and position the caliper aside.





4. Remove the 2 brake pads and if equipped, remove the 4 retraction clips.
^ Discard the retraction clips.
5. Measure the front brake disc thickness.
^ Install a new front brake disc if it is not within specification.

6. CAUTION: Install new brake pads if they are worn past the specified thickness above the metal backing plates. Install new brake pads in complete axle sets.

Inspect the brake pads for wear and contamination.

Installation





1. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the pad lining material. Do not install contaminated pads.

NOTE: Install all new hardware as supplied with the brake pad kit.

Install the 4 new retracting clips and the 2 brake pads.





2. CAUTION: Protect the piston and boots when pushing the caliper piston into the caliper piston bores.

Using a suitable tool, compress the disc brake caliper pistons into the caliper.





3. CAUTION: Tighten the bottom caliper bolt before tightening the top caliper bolt

CAUTION: Make sure the caliper pin boots are correctly seated to prevent damage to the guide pins.

Position the brake caliper and install the 2 bolts.
^ On F-250, F-350, tighten to 76 Nm (56 ft. lbs.).
^ On F-450, F-550, tighten to 63 Nm (46 ft. lbs.).
4. Fill the brake master cylinder reservoir with clean brake fluid.
5. Test the brakes for normal operation.