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 vehicle from rolling.
* Lug Wrench: To remove the wheels.
* Socket Wrench Set: With the appropriate sizes for your caliper bolts and lug nuts.
* C-Clamp or Brake Caliper Compression Tool: To compress the caliper piston. A C-clamp works in a pinch, but a dedicated tool is preferred.
* Pliers: Possibly needed to remove caliper retaining pins or clips.
* Wrench or Socket for Bleeder Screw (optional): If you need to bleed the brakes afterwards.
* Brake Cleaner: To clean the caliper and brake parts.
* New Brake Pads: Make sure you get the correct pads for your 1991 F-150.
* Gloves: To keep your hands clean.
* Penetrating Oil (like PB Blaster): May help loosen stubborn bolts.
Procedure:
1. Safety First: Park on a level surface, engage the parking brake, and chock the rear wheels. Jack up the front of the truck and securely support it on jack stands.
2. Remove the Wheel: Remove the lug nuts and take off the wheel.
3. Locate the Caliper: Identify the brake caliper which is a metal housing clamping onto the rotor.
4. Expose the Caliper Bolts: You'll need to locate the bolts that hold the caliper to the caliper bracket. These are usually on the backside of the caliper.
5. Remove Caliper Bolts: Carefully remove the caliper bolts. Sometimes they can be seized, so penetrating oil may be helpful.
6. Compress the Caliper Piston: This is crucial. Use the C-clamp or brake caliper compression tool to push the caliper piston back into the caliper housing. You'll need to push it in fairly firmly as the new pads are thicker. *Be aware that brake fluid will be pushed back into the brake lines. You may want to have a catch container ready.*
7. Remove the Old Brake Pads: Once the caliper piston is compressed, the old brake pads should slide out.
8. Clean the Caliper and Bracket: Use brake cleaner to thoroughly clean the caliper, caliper bracket, and rotor surface. Make sure everything is free of debris and grease.
9. Install the New Brake Pads: Carefully slide the new brake pads into place in the caliper.
10. Reinstall the Caliper: Carefully mount the caliper back onto the caliper bracket and tighten the caliper bolts to the manufacturer's specified torque (check your owner's manual or a repair manual).
11. Reinstall the Wheel: Put the wheel back on and tighten the lug nuts.
12. Lower the Vehicle: Carefully lower the vehicle from the jack stands.
13. Check for Proper Function (Crucial): After lowering, carefully pump the brake pedal several times to ensure the brakes are functioning properly. *If the pedal feels soft or goes to the floor, you likely have air in the brake lines and will need to bleed the brakes.*
Important Considerations:
* Rotor Condition: Inspect the brake rotors for wear and tear. If they're excessively grooved or worn, they'll need to be replaced or resurfaced.
* Brake Fluid Level: Monitor your brake fluid level. If it's low after compressing the caliper piston, you may need to add brake fluid.
* Brake Bleeding: If you have to replace the brake lines or encounter any situations resulting in air in the lines, you will have to bleed the brakes. This is a separate procedure which requires an extra person. Consult a repair manual for instructions.
* Repair Manual: A Haynes or Chilton repair manual specific to your 1991 Ford F-150 is highly recommended. It will have detailed instructions, diagrams, and torque specifications.
This is a general guide. Specific procedures may vary slightly depending on your truck's configuration. Always consult a repair manual for your specific vehicle model before starting this repair. If you are not comfortable performing this repair yourself, take your vehicle to a qualified mechanic. Brake safety is not something to take lightly.
