Disclaimer: This information is for educational purposes only. Working on brakes is potentially dangerous. If you're not comfortable performing this repair, take your vehicle to a qualified mechanic. Improper brake repair can lead to serious injury or death.
Tools You'll Need:
* Jack and jack stands (crucial for safety!)
* Lug wrench
* Wheel chocks
* Socket wrench set (metric)
* Wrenches (metric)
* Brake caliper pliers or C-clamp
* Hammer
* Pry bar (possibly)
* Wire brush
* Brake cleaner
* New brake pads
* Possibly new caliper bolts (inspect them; replace if necessary)
* Possibly new rotors (inspect them; replace if necessary, especially if scored or warped)
* Anti-seize compound
* Gloves
* Safety glasses
Steps:
1. Safety First: Park on a level surface, engage the parking brake, and use wheel chocks on the rear wheels. Jack up the front of the truck, securely supporting it on jack stands. Never work under a vehicle supported only by a jack.
2. Remove the Wheel: Remove the lug nuts and carefully remove the wheel.
3. Inspect the Rotors and Pads: Visually inspect the brake rotors for scoring, warping, or excessive rust. Inspect the brake pads for wear. Replace rotors and pads if necessary. The minimum thickness for brake pads is usually stamped on the pad itself or can be found in your owner's manual. A minimum rotor thickness is also usually specified.
4. Remove the Caliper:
* Push back the caliper piston: Using a caliper piston compression tool or C-clamp, carefully compress the caliper piston to make room for the new, thicker brake pads. This might require some force. Be careful not to damage the piston seal. You may need to periodically open the brake fluid reservoir to avoid overflowing.
* Unbolt the caliper: Locate the caliper mounting bolts and carefully remove them. They're usually on the back side of the caliper. Support the caliper with your hand or a bungee cord to prevent it from hanging by the brake line.
5. Remove the Brake Pads: Carefully remove the old brake pads from the caliper bracket.
6. Clean: Use a wire brush and brake cleaner to thoroughly clean the caliper bracket, caliper piston, and rotor mating surfaces.
7. Install New Brake Pads: Install the new brake pads into the caliper bracket.
8. Install the Caliper: Carefully reinstall the caliper onto the caliper bracket, ensuring the caliper slides freely. Tighten the caliper mounting bolts to the manufacturer's specified torque.
9. Reinstall the Wheel: Reinstall the wheel and tighten the lug nuts to the manufacturer's specified torque.
10. Lower the Vehicle: Carefully lower the vehicle to the ground.
11. Repeat for the Other Side: Repeat steps 2-10 for the other front wheel.
12. Pump the Brakes: Start the engine and gently pump the brake pedal several times to build up pressure. Check for leaks.
13. Test Drive: Take a short test drive to ensure the brakes are functioning correctly.
Important Considerations:
* Brake Fluid: If you're dealing with excessive brake fluid loss or are replacing components like calipers, you'll likely need to bleed the brakes to remove air from the system. This requires a helper. There are many tutorials available online showing this procedure.
* Torque Specifications: Always consult a torque specification chart for your vehicle to ensure you tighten bolts to the correct torque. Over-tightening can damage components, while under-tightening can lead to loosening and failure.
* Rust: On older vehicles, rust can be a major problem. Penetrating oil may be necessary to help loosen stubborn bolts.
This is a general guide. Variations exist between different models of Ford trucks. Refer to a repair manual specific to your 1991 Ford truck for detailed instructions and diagrams. Remember, safety is paramount. If you have any doubts, consult a qualified mechanic.
