Here's a general outline. Specific steps may vary depending on your exact truck model (F-150, F-250, etc.) and trim level. Always consult a repair manual specific to your truck for detailed instructions and torque specifications.
Tools You'll Need:
* Jack and jack stands: Absolutely essential for safety. Never work under a vehicle supported only by a jack.
* Wheel chocks: To prevent the truck from rolling.
* Lug wrench: To remove the wheels.
* Socket wrench set: Various sizes, including metric and possibly SAE.
* C-clamp or caliper compression tool: To compress the caliper piston.
* Torque wrench: Crucial for tightening bolts to the correct specification.
* Brake caliper piston wind-back tool: Helps to turn the caliper piston when compressing it. (Some use a C-clamp, but a dedicated tool works better).
* Wire brush: To clean caliper surfaces.
* Penetrating oil (PB Blaster, etc.): To loosen rusted bolts.
* New brake pads and rotors: Make sure you get the correct parts for your truck.
* Gloves: To keep your hands clean and protect from brake dust.
* Safety glasses: To protect your eyes from flying debris.
* Shop rags or paper towels: For cleaning.
Steps (General Outline):
1. Safety First: Engage the parking brake firmly. Place wheel chocks behind the rear wheels. Jack up the front of the truck securely and place it on jack stands.
2. Remove the Wheel: Remove the lug nuts and take off the wheel.
3. Remove the Caliper: Locate the caliper mounting bolts. They're usually on the back of the caliper. Spray penetrating oil on the bolts if they're stuck. Unscrew the bolts and carefully remove the caliper. You may need to support the caliper with a bungee cord or wire to keep it from hanging by the brake line.
4. Compress the Caliper Piston: Use the C-clamp or caliper compression tool to slowly and evenly compress the caliper piston. This will create space for the new, thicker brake pads. Be careful not to damage the piston seal. Some pistons require turning while compressing to avoid damage.
5. Remove the Old Brake Pads: The old pads should now be easily removable.
6. Remove the Rotors: Usually, there are caliper mounting bracket bolts securing the caliper bracket to the steering knuckle. Remove those bolts. Then remove the rotor. If the rotor is very difficult to remove, use a rubber mallet to tap it off. Inspect the wheel studs and clean them up.
7. Install the New Rotors: Install the new rotors onto the wheel studs.
8. Install the New Brake Pads: Insert the new brake pads into the caliper.
9. Reinstall the Caliper: Carefully reattach the caliper to the bracket, ensuring it's properly seated. Tighten the mounting bolts to the correct torque specification (check your repair manual).
10. Reinstall the Wheel: Tighten the lug nuts to the correct torque specification. Don't overtighten!
11. Repeat for the Other Side: Follow the same steps for the other front wheel.
12. Lower the Truck: Carefully lower the truck from the jack stands.
13. Test the Brakes: Before driving, carefully pump the brake pedal several times to ensure the brakes are functioning correctly. Take the truck for a short, careful test drive to fully bed in the new pads and rotors. The brakes may feel slightly different at first.
Important Considerations:
* Bleeding the Brakes: You might not need to bleed the brakes if you didn't open the brake lines, but it's good practice to check for any air bubbles in the lines and bleed them if needed.
* Brake Fluid: Check and top off your brake fluid reservoir as needed.
* Repair Manual: Obtain a repair manual specific to your 1996 Ford truck. This will provide detailed diagrams and torque specifications. These are essential for a safe and successful repair.
Again, if you're not comfortable performing this repair, take your truck to a qualified mechanic. Brake safety is not something to compromise on.
