Tools you will likely need:
* Jack and jack stands (rated for the weight of your truck)
* Lug wrench
* Wheel chocks
* Socket set (metric) with extensions and ratchets
* Torque wrench
* C-clamp or brake caliper compressor tool
* Brake cleaner
* Wire brush
* Pliers
* Hammer (possibly)
* New brake pads and rotors (or drums if your truck has drum brakes in the rear; this guide assumes disc brakes at all four wheels, which is more common)
* New caliper bolts (recommended)
* Lubricant (brake caliper grease)
Step-by-step instructions (for disc brakes at all four wheels - check your truck):
Front Brakes:
1. Safety First: Park on a level surface, engage the parking brake, and chock the rear wheels.
2. Jack Up and Secure: Jack up the front of the truck and securely place it on jack stands. Never work under a vehicle supported only by a jack.
3. Remove Wheel: Remove the lug nuts and carefully remove the wheel.
4. Caliper Removal: Locate the caliper mounting bolts. They are usually on the top and bottom of the caliper. Remove these bolts. Sometimes the caliper slides off easily, other times you need to carefully compress the caliper piston (see step 5). Support the caliper with a wire or bungee cord to prevent it from hanging by the brake line.
5. Compress Caliper Piston: Use a C-clamp or specialized brake caliper compressor tool to compress the caliper piston. This creates space for the new, thicker brake pads. You may need to twist and push the piston as you compress it.
6. Remove Brake Pads: Carefully remove the old brake pads.
7. Inspect Rotor: Inspect the rotor for excessive wear, scoring, or warping. If necessary, replace the rotor.
8. Clean: Clean the caliper and rotor surfaces with brake cleaner. Use a wire brush to remove any rust or debris.
9. Install New Pads: Install the new brake pads, ensuring they are properly seated.
10. Install Caliper: Install the caliper, making sure the caliper slides freely. Attach the caliper mounting bolts and tighten to the manufacturer's specified torque (check your repair manual). Use new bolts if available.
11. Lubricate: Apply brake caliper grease to the caliper pins and sliding surfaces.
12. Repeat: Repeat steps 4-11 for the other front wheel.
13. Lower and Test: Lower the truck, carefully remove jack stands, and check for proper brake operation. Test the brakes gently at low speed before driving normally.
Rear Brakes:
The rear brake replacement process is similar, but there are some differences depending on whether your truck has disc or drum brakes. This guide focuses on rear disc brakes:
1. Repeat Steps 1-3 (from Front Brakes section).
2. Caliper Removal (Rear): The process of removing and reinstalling the rear calipers is generally similar to the front calipers, but bolt locations and caliper designs might vary.
3. Compress Caliper Piston: Again, compress the caliper piston before removing the old pads.
4. Inspect Rotor (Rear): Check the rotor condition and replace if necessary.
5. Clean: Clean the caliper and rotor surfaces with brake cleaner.
6. Install New Pads (Rear): Install new pads, ensuring they're correctly seated.
7. Install Caliper (Rear): Reinstall the caliper, lubricating the caliper pins and sliding surfaces with brake caliper grease. Torque the bolts to the manufacturer's specification.
8. Repeat Steps 2-7: For the other rear wheel.
9. Lower and Test: Lower the truck, check for proper brake operation, and test gently before normal driving.
Important Considerations:
* Bleeding Brakes: After replacing brake components, you may need to bleed the brakes to remove air from the lines. This requires two people and a bleeding kit. Consult your repair manual for the proper bleeding procedure.
* Torque Specifications: Always refer to your vehicle's repair manual for the correct torque specifications for all bolts. Over-tightening can damage components.
* Parking Brake: If your parking brake is cable-operated, you might need to adjust it after replacing the rear brakes.
* ABS System: If your truck has an Anti-lock Braking System (ABS), be aware that some ABS systems require specialized diagnostic tools to properly address any issues that arise during brake work.
This is a general guide. Always consult a detailed repair manual for your specific 2001 Ford F250 Super Duty 4WD. Improper brake repair can be dangerous; if unsure, consult a qualified mechanic.
