How to Remove the Brake Pads on a 1986 Econoline E-250

The 1986 Ford E-250 came with a 4.9-liter V-6 engine as the base model engine. A 5.0-liter V-8, a 5.8-liter V-8, a 6.9-liter Diesel V-8 and a 7.5-liter V-8 were all optional engines for the 1986 E-250. The E-250 used disc brakes on the front of the van and drum brakes on the rear. The disc brakes on the front of the E-250 used a heavy-duty, dual-piston caliper. Locking pins were used on the caliper of the 1986 E-250, versus the more common screw-style caliper pins of modern-day vehicles.

Instructions

1

Open the hood of the E-250. Use a small pump siphon or turkey baster to remove the brake fluid, until the fluid is about 1/2 inch below the "Full" mark.

2

Loosen the front lug nuts on the E-250, using a tire iron. Raise the front of the van on a jack. Place jack stands beneath the front frame rails, just inward from the lower control arms. Lower the E-250 onto the jack stands. Remove the lug nuts completely from the van, then remove the front wheels.

3

Install a large C-clamp around the outside of one of the front calipers and the caliper-mounting bracket on the rear of the caliper. Compress the caliper inward toward the center of the van, but do not press so hard that you will crack the caliper.

4

Insert a punch awl into the upper caliper-holding pin. Tap the awl with a hammer to push the pin inward through the mounting hole. Pull the upper mounting pin free from the rear side of the caliper, using pliers or channel locks. Repeat this step to remove the lower caliper-mounting pin. Pull the caliper free using a small pry bar if needed. Hang the caliper from the front-coil spring assembly, using a metal clothes hanger or metal hook. Do not let the caliper hang from the brake hose to which it attaches.

5

Install an old brake pad against the caliper pistons on the inside of the caliper. Attach your C-clamp around the old brake pad and the rear of the caliper housing. Tighten the C-clamp slowly, to compress the caliper pistons completely. Remove the C-clamp and the old brake pad when the caliper pistons compress completely into the caliper.

6

Inspect your brake rotor for gouges, pitting or warp lines. If you see physical imperfections in the rotor, replace the rotor at this time. Measure across the top of the rotor to gain the thickness of the rotor, using a tape measure. The measurement should be no less than 1 inch thick. If the rotor is close to or less than 1 inch thick, then replace the rotor at this time.

7

Install a new wear indicator onto the upper end the inboard brake pad, if it is not equipped with one from the factory. Install the inboard and outboard brake pads onto the caliper bracket. Install the anti-rattle spring onto the pads. Apply a thin coat of disc brake grease onto the outer shim plates of the new pads.

8

Install the caliper over the new brake pads. Thoroughly grease the caliper pins. Insert the caliper pins inward from the outside the mounting hole. Install your punch awl against the lower pin, and tap the pin inward until the split end of the pin rests against the outside lip of the caliper. Flare the end of the pin outward to lock it in place, using needle-nose pliers. Repeat this step to install the upper caliper pin and secure it.

9

Repeat steps 3 through 8 to complete the brake pad replacement on the second side of the E-250. Install the front wheels and tighten all of the lug nuts snug, using tire iron. Raise the van off of the jack stands, then remove the stands from beneath the van. Lower the E-250 to the ground. Tighten the front wheel lug nuts to 140 foot-pounds in a "star" shaped pattern, using a 1/2-inch-drive torque wrench and wheel nut socket.