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how to replace brakes on 1999 Ford Expedition


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If you need to replace the brakes, first you need to find out what parts are going to be needed.

I would recommend replacing the pads and rotors at the same time. If not you will need to have the old rotors resurfaced. This will prevent vibrations while braking.


REMOVAL & INSTALLATION



Front Pads



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Fig. Fig. 1 Caliper mounting bolt locations




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Fig. Fig. 2 Loosen the caliper mounting bolts




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Fig. Fig. 3 The pads can be accessed by removing the lower caliper bolt and rotating the caliper up as shown




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Fig. Fig. 4 Support the caliper with a piece of mechanic's wire or other suitable device




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Fig. Fig. 5 Remove the outer and ...




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Fig. Fig. 6 ... inner brake pads from the caliper bracket




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Fig. Fig. 7 A special tool from Lisle®, shown here, is available to compress the caliper piston




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Fig. Fig. 8 If the special tool is not available, a large C-clamp works well




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Fig. Fig. 9 Thoroughly clean the caliper brackets before installing the new pads




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Fig. Fig. 10 Remove the caliper slides and ...




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Fig. Fig. 11 ... thoroughly clean the slides




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Fig. Fig. 12 Lubricate the caliper slides before reinstalling them into the caliper bracket




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Fig. Fig. 13 Make sure that the caliper tension spring is installed into the caliper before installing the caliper




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Fig. Fig. 14 Before installing the brake pads, it is recommended that you apply a suitable anti-squeal lubricant to the pads and ...




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Fig. Fig. 15 ... spread the lubricant evenly over the backing of the brake pads



CAUTION
Older brake pads or shoes may contain asbestos, which has been determined to be cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.



  1. To avoid overflowing of the master cylinder when the caliper pistons are pressed into the caliper cylinder bores, siphon or dip some brake fluid out of the larger reservoir.

  2.  




CAUTION
Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance.



  1. Raise and support the vehicle on jackstands.
  2.  
  3. Remove the wheels.
  4.  
  5. Place an suitable C-clamp on the caliper and, with the clamp bearing on the outer pad, tighten the clamp to bottom the caliper pistons in the cylinder bores. Remove the C-clamp.
  6.  
  7. Loosen and remove the caliper retaining bolts.
  8.  
  9. Lift the caliper off of the rotor.

  10.  


Do not allow the caliper to hand by the brake hose.

  1. Remove the brake pads and anti-rattle spring.
  2.  


To install:

  1. Thoroughly clean the areas of the caliper and spindle assembly which contact each other during the sliding action of the caliper.
  2.  
  3. Place a new anti-rattle clip on the lower end of the inboard shoe. Make sure that the tabs on the clip are positioned correctly and the loop-type spring is away from the rotor.
  4.  
  5. Place the lower end of the inner brake pad in the spindle assembly pad abutment, against the anti-rattle clip, and slide the upper end of the pad into position. Be sure that the clip is still in position.

  6.  
  7. Check and make sure that the caliper piston is fully bottomed in the cylinder bore. Use a large C-clamp to bottom the piston, if necessary.
  8.  
  9. Position the outer brake pad on the caliper, and press the pad tabs into place with your fingers. If the pad cannot be pressed into place by hand, use a C-clamp. Be careful not to damage the lining with the clamp. Bend the tabs to prevent rattling.
  10.  
  11. Position the caliper on the spindle assembly. Lightly lubricate the caliper sliding pins with a suitable grease.

  12.  
  13. Position the caliper pins into the caliper anchor plate.
  14.  
  15. Tighten the caliper pins to 16-30 ft. lbs. (22-40 Nm) on 19997-98 F-250HD, F-350 and F-Super duty models. Tighten the caliper pins to 21-26 ft. lbs. (28-36 Nm) on the F-150, F-250, Expedition and Navigator. Tighten the caliper pins to 42 ft. lbs. (56 Nm) on the 1999-00 F-250SD, F-350 and F-Super Duty models.
  16.  
  17. Install the wheels.
  18.  
  19. Lower the vehicle.
  20.  
  21. Pump the brake pedal a few times to build adequate pressure in the brake system and check the fluid level in the master cylinder.
  22.  


Rear Pads
1997-98 F-SUPER DUTY MODELS



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Fig. Fig. 16 Brake caliper assembly-1997-98 F-Super Duty models



CAUTION
Older brake pads or shoes may contain asbestos, which has been determined to be cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.


Never replace the pads on one side only! Always replace pads on both wheels as a set!

  1. To avoid overflowing of the master cylinder when the caliper pistons are pressed into the caliper cylinder bores, siphon or dip some brake fluid out of the larger reservoir.
  2.  
  3. Raise and support the rear end on jackstands.
  4.  
  5. Remove the wheels.
  6.  
  7. Place a suitable C-clamp on the caliper and tighten the clamp to bottom the caliper pistons in the cylinder bores. Remove the C-clamp.
  8.  
  9. Clean the excess dirt from around the caliper pin tabs.
  10.  
  11. Drive the upper caliper pin inward until the tabs on the pin touch the caliper support.
  12.  
  13. Insert a small prybar into the slot provided behind the pin tabs on the inboard side of the pin.

  14.  
  15. Using needlenose pliers, compress the outboard end of the pin while, at the same time, prying with the prybar until the tabs slip into the groove in the caliper support.
  16.  

  17. Place the end of a
    7
    /
    16

    in. (11mm) punch against the end of the caliper pin and drive the pin out of the caliper slide groove.

  18.  
  19. Repeat this procedure for the lower pin.
  20.  
  21. Lift the caliper off of the rotor.
  22.  
  23. Remove the brake pads and anti-rattle spring.

  24.  


Do not allow the caliper to hand by the brake hose.

  1. Thoroughly clean the areas of the caliper and caliper support assembly which contact each other during the sliding action of the caliper.
  2.  


To install:

  1. Place a new anti-rattle clip on the lower end of the inboard shoe. Make sure that the tabs on the clip are positioned correctly and the loop-type spring is away from the rotor.
  2.  
  3. Place the lower end of the inner brake pad in the caliper support assembly pad abutment, against the anti-rattle clip, and slide the upper end of the pad into position. Be sure that the clip is still in position.
  4.  
  5. Check and make sure that the caliper pistons are fully bottomed in the cylinder bores. Use a large C-clamp to bottom the pistons, if necessary.

  6.  
  7. Position the outer brake pad on the caliper, and press the pad tabs into place with your fingers. If the pad cannot be pressed into place by hand, use a C-clamp. Be careful not to damage the lining with the clamp. Bend the tabs to prevent rattling.
  8.  
  9. Position the caliper on the caliper support. Lightly lubricate the caliper sliding grooves with caliper pin grease.
  10.  
  11. Position the a new upper pin with the retention tabs next to the support groove.
  12.  


Don't use the bolt and nut with the new pin.

  1. Carefully drive the pin, at the outboard end, inward until the tabs contact the caliper support face.
  2.  
  3. Repeat the procedure for the lower pin.
  4.  




WARNING
Don't drive the pins in too far, or it will be necessary to drive them back out until the tabs snap into place. The tabs on each end of the pin MUST be free to catch on the support sides!



  1. Install the wheels.
  2.  
  3. Lower the vehicle.

  4.  
  5. Pump the brake pedal a few times to build adequate pressure in the brake system and check the fluid level in the master cylinder.
  6.  


EXCEPT 1997-98 F-SUPER DUTY MODELS


CAUTION
Older brake pads or shoes may contain asbestos, which has been determined to be cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.


Never replace the pads on one side only! Always replace pads on both wheels as a set!

  1. Remove the rear brake caliper from the rear hub without disconnecting the brake hose.
  2.  




WARNING

Do not allow the caliper to hand by the brake hose.



  1. Remove the brake pads and anti-rattle spring.
  2.  
  3. Thoroughly clean the areas of the caliper and caliper support assembly which contact each other during the sliding action of the caliper.
  4.  


To install:

  1. Retract the caliper piston into the caliper using a suitable tool.
  2.  
  3. Position the brake shoes and anti-rattle clips on the disc brake caliper support bracket.
  4.  
  5. Install the rear disc brake caliper onto the rear support bracket. Tighten the caliper retaining pins on the F-150, F-250, Expedition and Navigator to 20 ft. lbs. ( 27 Nm). Tighten the caliper retaining bolts on the 1999-00 F-Super Duty models to 27 ft. lbs. (36 Nm.)

  6.  
  7. Bleed the brake system.
  8.  
  9. Clean the wheel hub mounting surface.
  10.  
  11. Install the front wheels and snug the lug nuts to fully seat the wheel against the hub.
  12.  
  13. Lower the vehicle until some of the vehicle's weight rests on the front tires, then tighten the lug nuts to 83-112 ft. lbs. (113-153 Nm).
  14.  
  15. Lower the vehicle completely.
  16.  
  17. Pump the brake pedal a few times to build adequate pressure in the brake system and check the fluid level in the master cylinder.
  18.  


INSPECTION






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Fig.
Fig. 17 A gauge that measures in
1
/
32
's of an inch is available to measure brake pad thickness




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Fig. Fig. 18 A ruler can also be used. Make sure to measure the pads in several places since pads can wear unevenly



CAUTION
Older brake pads or shoes may contain asbestos, which has been determined to be cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.


Inspect the brake pads for wear using a ruler, Vernier caliper or other suitable device. Compare measurements to the brake specifications chart. If the lining is thinner than specification or there is evidence of the lining being contaminated by brake fluid or oil, make the necessary repairs and replace all brake pad assemblies (a complete axle set).


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