* Worn brake pads: This is the most common issue.
* Worn rotors: Rotors can wear down unevenly or become grooved.
* Brake caliper issues: Seized calipers, leaking seals, or sticky pistons.
* Brake lines/hoses: Leaks or damage.
* Master cylinder: Internal leaks or failure.
* ABS problems (if equipped): Issues with the Anti-lock Braking System.
Before you start ANY brake work:
* Safety First: This is crucial. Work in a well-ventilated area. Wear safety glasses and gloves. Use jack stands, never rely solely on a jack. Disconnect the negative battery terminal to prevent accidental shorts.
* Gather tools: You'll need a socket wrench set (metric), a wrench set, pliers, a C-clamp (possibly), brake cleaner, a wire brush, possibly a caliper piston compressor tool, new brake pads, and possibly new rotors. Refer to a repair manual specific to your 1996 Ford Ranger for the exact tools and torque specs.
* Consult a repair manual: A Haynes or Chilton manual for your specific year and model Ranger is invaluable. It will provide detailed instructions with diagrams. Online resources like YouTube can be helpful, but always double-check with a reputable manual.
General Steps (for worn brake pads and rotors – the most common scenario):
1. Diagnosis: Check your brake pads' thickness. If they're worn below the minimum thickness specified in your repair manual, they need replacing. Inspect the rotors for scoring, grooves, or excessive wear. If the rotors are severely damaged, they'll need replacing too.
2. Jack up the truck: Securely lift the front of your Ranger using a jack and place it on jack stands.
3. Remove the wheel: Remove the wheel lug nuts and take off the wheel.
4. Remove the caliper: Depending on your Ranger's model, you might need to remove a caliper bracket bolt and possibly disconnect the brake line (carefully!). Some calipers slide off easily; others might require more effort. Support the caliper with a wire or bungee cord to prevent it from hanging by the brake line.
5. Remove the brake pads: Remove the old brake pads. Inspect the caliper slides for movement; they should slide freely. Clean them with a wire brush and brake cleaner. Lubricate the slide pins with high-temperature brake caliper grease (not general-purpose grease).
6. Inspect and replace rotors (if necessary): Inspect the rotors for damage. If they're worn or damaged, they must be replaced. If replacing, you'll need to remove them.
7. Install new brake pads: Install the new brake pads.
8. Install the caliper: Carefully install the caliper, ensuring it's properly seated.
9. Compress the caliper piston: Use a C-clamp or a specialized caliper piston compressor tool to compress the caliper piston. This is necessary to make room for the new, thicker brake pads. Be careful not to damage the piston seal.
10. Reinstall the wheel: Replace the wheel and tighten the lug nuts to the manufacturer's specified torque.
11. Repeat for the other side: Repeat steps 3-10 for the other front wheel.
12. Bleed the brakes (important!): After replacing brake pads or doing any work on the brake system, you *must* bleed the brakes to remove any air bubbles from the brake lines. This is best done with a friend to help pump the brake pedal. Consult your repair manual for the proper bleeding procedure.
13. Test the brakes: Test your brakes carefully in a safe, open area before driving your truck normally.
If you encounter any other problems (e.g., seized calipers, leaking lines), you'll need to address those specifically. Do not attempt repairs beyond your skill level. If you are uncomfortable with any of these steps, take your Ranger to a qualified mechanic. Improper brake repair can be extremely dangerous.
