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Some 2004/2005 F-150 vehicles built before 11/29/2004 may exhibit front brake roughness and or shudder while braking. ACTION Service the rack and pinion, rotors, and caliper assemblies as needed, based on vehicle build date and current part levels installed on the vehicle. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Vehicles built prior to 8/20/2003 require the replacement of the rack and pinion assembly if it has not been replaced. Refer to Workshop Manual, Section 206-03 and 211-02. 2. Determine if the vehicle has the old or new level rotors (Figure 1).WHEN REPLACING THE ROTORS ON 4X2 UNITS, A NEW SPINDLE NUT IS REQUIRED. b. If new level (47 fin) rotors are present, perform one (1) of the following: (1) (2) If rotors are within minimum thickness specifications, machine the rotors using the Rotunda on vehicle brake lathe and the Rotunda adapter kit 201-R0093. Refer to the Workshop Manual, Section 206-00 for the correct on-vehicle brake lathe procedure. If rotors are beyond machinable thickness, the front rotors must be replaced. 3. Install new service fix calipers. NOTE REPLACE CALIPERS WITH NEW SERVICE FIX CALIPER ASSEMBLIES BY REMOVING THE CALIPERS AT THE KNUCKLES. THE SERVICE REPLACEMENT CALIPERS WILL BE PRE-ASSEMBLED WITH ANCHOR, SPRINGS, AND PADS. THE CALIPERS SHOULD BE INSTALLED AS A UNIT WITHOUT DISASSEMBLY.

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NOTE: Minimum thickness for replacing the brake pads = 3.0 mm . Remove the securing spring and locating pins Remove: the securing spring (3) carefully so that it does not deform the protective caps (1) from the two locating pins (2) the locating pins, use hex socket 7 mm . Remove the brake caliper and brake pads Remove: the brake caliper from the holder the brake pads. Hang brake caliper from a steel wire from the front spring so as not to damage brake hose. NOTE: Do not depress the brake pedal while the brake pads are removed. Clean and check brake caliper and dust cover Brake Pads, Rear, Replacing Removal NOTE: Minimum thickness for replacing the brake pads = 3.0 mm . Remove retaining springs and locating pins for brake pads Remove:

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2. INSPECT PAD LINING THICKNESS Check the pad thickness through the caliper inspection hole and replace pads if the thickness is not within the specification. Minimum thickness: 1.0 mm (0.039 inch) 3. REMOVE ANTI-SQUEAL SPRING AND PAD GUIDE PIN a. Raise the “B” portion with hand, push up the “A” portion and unlatch the anti-squeal spring from brake caliper. b. Remove the anti-squeal spring. NOTICE: Do not deform the clip and anti-squeal spring. The clip and anti-squeal spring can be used again provided that they have sufficient rebound, no-deformation, cracks or wear, and have had all rust, dirt and foreign particles cleaned off. c. Remove the clip and pad guide pin. 4. REMOVE PADS AND ANTI-SQUEAL SHIMS a. Remove the 2 pads. b. Remove the 4 anti-squeal shims from each pad. 5. CHECK DISC THICKNESS AND RUNOUT 6. INSTALL NEW PADS NOTICE: When replacing worn pads, the anti-squeal shims must be replaced together with the pads. a. Apply disc brake grease to both sides of inner anti-squeal shims. b. Install the 2 anti-squeal shims on each pad. HINT: Make sure the arrows on the inner anti-squeal shims facing to the direction of disc rotation as shown in the illustration. c. Draw out a small amount of brake fluid from the reservoir.

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FRONT DISC BRAKE CALIPER Removal & Installation Raise and support front of vehicle. Remove front wheel assemblies and disconnect brake hose. Plug all openings. Remove front disc brake pads. See FRONT DISC BRAKE PADS . Remove remaining mounting bolt(s). Remove caliper from vehicle. To install, reverse removal procedure. Bleed air from system. FRONT BRAKE ROTOR Removal & Installation 1. Raise and support front of vehicle. Remove front wheel assemblies. Remove front disc brake caliper with brake hose connected. See FRONT DISC BRAKE CALIPER . Wire caliper aside. Remove rotor-to-hub screws (if equipped). Remove rotor. 2. Machine rotor if lateral runout exceeds specification. Replace rotor if measured thickness is less than specified minimum thickness. See DISC BRAKE SPECIFICATIONS table. To install, reverse removal procedure. REAR DISC BRAKE PADS Removal & Installation