B1 .JPG 2581 hits | 87.28 KB | Posted: 7/13/03 Rotor Scored by excessive wear on pad
B11.JPG 2254 hits | 105.58 KB | Posted: 7/13/03 Rotor Scored severely by pad lining missing.
Brake Rotor Wear.JPG 2172 hits | 88.12 KB | Posted: 1/13/06 This rotor was allowed to wear completely through the inner surface, exposing the vent fins. The dr...
Brake Rotor Wear.JPG 966 hits | 88.39 KB | Posted: 12/10/04 This is the result of the pad wearing away, then its backing plate eating off the inner surface of a...
AutoLock5Screw.jpg 3910 hits | 41.35 KB | Posted: 1/14/05 5-Screw Auto Hub Lock
These use a single thick splined shim between the C-clip & the spindle to hol...
AutoHubLocksOp.jpg 2893 hits | 62.14 KB | Posted: 1/1/07 Early 5-screw auto hub lock operation.
Regarding part #3: I think the double-lip faces INboard (toward the diff) so t...
HubLocksNew.JPG 1916 hits | 53.12 KB | Posted: 9/18/07 You don't have to spend $130/pr on Warn Premium hub locks to get a lifetime warranty. And the Warns...
HubLockManual95up.jpg 3418 hits | 73.14 KB | Posted: 1/2/06 Manual Hub Locks
These use 3 washers (15,16,17) between the C-clip & the spindle to hold the axle s...
FlangeHubLocks.jpg 3065 hits | 33.92 KB | Posted: 1/1/07 Flange-style manual hub locks used only on '87-early '88 F150s & Broncos w/manual locks. '87-88 w/a...
B4.JPG 5372 hits | 78.47 KB | Posted: 7/13/03 '80-96 rotor replacement requires removing the hub assembly & driving out the lug studs. On '93-96 ...
B49.JPG 3085 hits | 85.1 KB | Posted: 7/13/03 Rotor Installation
1. Set the rotor onto the back of the hub.
2. Drive the lug studs through both...
B5.JPG 3288 hits | 83.15 KB | Posted: 7/13/03 Front ABS Sensors on '93-96 Broncos only. Clean metal filings. Retainer bolt inside steering knuck...
SensorShield.JPG 125 hits | 93.15 KB | Posted: 9/28/09 The bolt for this shield has an extremely odd 12-point head, so most people (including me) don't car...
B44.jpg 3266 hits | 92.05 KB | Posted: 7/13/03 Wheel Bearings Dry
Packing the hub with grease will prevent this, even when fording deep water.
B55.jpg 2943 hits | 66.85 KB | Posted: 7/13/03 2-piece Inner Wheel Seal used on '95?-96 1/2-ton 4WDs. It was NOT used on '93s, and can't be used w...
In addition to the ~'92 loss of a spindle stud (leaving 5) and the add...
B58.jpg 3976 hits | 90.18 KB | Posted: 7/13/03 Pack bearings, then fill void between bearings with Castrol Pyroplex Blue grease; not cheap grease a...
BearingNutAdjustment.jpg 3646 hits | 53.09 KB | Posted: 1/30/05 Wheel Bearing Nut adjustments. The L pane is the common 3-piece system; the R pane is the rare 1-pi...
Spanners.JPG 540 hits | 61.56 KB | Posted: 1/12/09 The L spanner is stronger & less likely to slip off a nut, but it won't work on a self-locking nut.
...
HubNutSelfLocking.jpg 2504 hits | 22.75 KB | Posted: 1/29/05 Rare self-locking hub nut used in the late '80s.
BrakeKeysBolts.JPG 2126 hits | 32.69 KB | Posted: 1/8/05 '83 Dana44IFS Brake caliper keys, slide springs, & bolts. Used from the late 70s until '85 on 2 & 4...
B60.JPG 2898 hits | 97.01 KB | Posted: 7/13/03 Torque lug nuts to 100 lb-ft, then retorque after 100 miles to fully seat lug studs.
[url=http://...
Lathe 01.JPG 1940 hits | 50.62 KB | Posted: 9/1/05 On-car brake lathe being set up. The adapter is installed & the cutter base is positioned on its ar...
Lathe 02.JPG 1523 hits | 49.44 KB | Posted: 9/1/05 On-car brake lathe. The motor is turned on, the automatic calibration process finishes, & the cutte...
Lathe 03.JPG 1423 hits | 50.26 KB | Posted: 9/1/05 On-car brake lathe. When the small knob on the radial control is pushed in, it is automatically dri...
Lathe 04.JPG 1490 hits | 51.76 KB | Posted: 9/1/05 On-car brake lathe. The first cut was not deep enough to resurface this badly worn rotor, so it is ...
Lathe 12.JPG 1389 hits | 86.78 KB | Posted: 9/1/05 On-car brake lathe. Same as 02, but without flash.
Lathe 13.JPG 1479 hits | 52.2 KB | Posted: 9/1/05 On-car brake lathe. Same as 03, but without flash.
Lathe 14.JPG 1670 hits | 86.66 KB | Posted: 9/1/05 On-car brake lathe. Same as 04, but without flash.
In the large controller connector, pin #1 is L top (530 LG/Y); pin #15 is L cent...
4WABSMod94.JPG 701 hits | 58.58 KB | Posted: 4/22/06 4WABS Module from a '94 Bronco
The "F4..." at the beginning fo the PN indicates it was designed i...
Crossdrilled&Slotted.jpg 1491 hits | 8.08 KB | Posted: 1/13/06 Cross-drilling is only for looks. On race cars, it reduces weight, but on trucks, it only makes the...
The basic components of the rear parking brake are shown. A cable from the f...
Brake Limiter.JPG 1369 hits | 58.98 KB | Posted: 1/13/06 Tension Limiter for early parking brake systems (pre-'92)
Equalizer.JPG 1331 hits | 124.47 KB | Posted: 7/21/03 This is the early e-brake tension limiter & equalizer. The upper cable is an aftermarket replacemen...
1 Control Assembly 2780
2 2 Nut M8 x 1.25 Hex Flange 17-23 N-m (13-17 Ft-L...
Cable Clip.JPG 1511 hits | 75.81 KB | Posted: 7/21/03 This is the easiest way to remove e-brake cable sheaths: slide a 1/2" box-end wrench over the end of...
Cable Release.JPG 1262 hits | 55.82 KB | Posted: 7/21/03 This is the easiest way to remove e-brake cable sheaths: slide a 1/2" box-end wrench over the end of...
Cablecut.JPG 1417 hits | 76.35 KB | Posted: 1/13/06 This e-brake cable was allowed to go slack inside the drum, probably due to a stuck autoadjuster and...
Other than 1/2" width, they're interchangeable.
ParkingBrakeSD.jpg 997 hits | 62.67 KB | Posted: 1/21/06 SD Park Brake
The parking brake is mounted to the transmission extension housing and incorporates a...
Hydro-Boost.jpg 943 hits | 53.29 KB | Posted: 1/13/06 Hydro-Boost
The Bendix Hydro-Boost brake booster is a hydraulically operated brake booster powered ...
Hydro-BoostRest.jpg 677 hits | 56.96 KB | Posted: 1/13/06 Hydro-Boost at Rest
With the Hydro-Boost at rest (engine on, brakes released) oil flows from the in...
Hydro-BoostGen.jpg 699 hits | 59.96 KB | Posted: 1/13/06 Hydro-Boost Generating Pressure
During normal power operation, the brake pedal is applied as shown ...
Hydro-BoostReserve.jpg 654 hits | 38.43 KB | Posted: 1/13/06 Hydro-Boost Reserve
The reserve braking system consists of a charging valve, an accumulator valve a...
Hydro-BoostManual.jpg 639 hits | 50.86 KB | Posted: 1/13/06 Hydro-Boost Manual
When reserve power is depleted (manual operation) pressure on the brake pedal wi...
Brakes & Hubs
