2000 Ford Expedition Logo
Nunyrbiz Feller Posted on Dec 14, 2013
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I have to replace all askspecs of my parking brakes on a

Everything is missing. Backing plate, shoes, pads, calipers, rotors, cables. Everything. I have 3 different manuals, Chilton's, Hayes, and Ford's Shop manual. None of them show how to replace all of it. I know hoe to do the shoes, the pads, rotors and calipers, But I do not know how to install the lever kit into the back plate. Please give feed back on what I need to do.

  • Nunyrbiz Feller Dec 14, 2013

    Have bought new lever kits 6L3Z-2A637-AR and AL from Ford Just do not know how to install them.

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1 Answer

Jerome Minks

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  • Ford Master 3,103 Answers
  • Posted on Dec 15, 2013
Jerome Minks
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Lever kit works the emergency (mechanical) brakes..the parts tore should have an assembly picture of this setup..there is also an exploded parts view of this ..it should show how it goes..

Testimonial: "Thanks Jerome. I got the part from Ford dealer, but it came with the parts in a bag with 2 rivets. God only knows what there for. The Bag came with a new boot, and 2 levers, and 2 rivets. One of levers has holes in it , and the other with a bigger ***, and a smaller ***. I think the smaller one is a stop, but not sure. What I can not figure out is how it mounts through the backing plate without falling out. It seems rather loose when I tried to install it on the new backing plate. I tried to install the brake shoes and all the springs without it being on the vehicle, so all I would have to do is pull the axles install the new back plates pr-loaded. I now see that is not going to work. I'm still looking all over the net to find how the levers are installed."

3 Related Answers

Anonymous

  • 350 Answers
  • Posted on Oct 17, 2008

SOURCE: 2006 Ford Five Hundred anti-lock brake pad replacement

hi its rare the pads stick to the rotor but obviously this one was welded metal to metal so if the other sides not down to the metal you won,t have the same problem now getting the piston back into the caliper if you don,t have the tool its going to be fiddling but you need to get some pressure on the piston as to shove it back in not to much as you have stated it has to be screwed back in once a pressure has been applied [could try using you c-clamp ] then the slots in the piston insert something that will turn the piston it will locate and start to screw back your going to need pateince as it is fiddling with the correct tool you may need a few attemps but the other side should not be as bad as the piston has not gone past the point of return take your time and check for leaks when you have them all assembled yates210456

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jefflaass

  • 5 Answers
  • Posted on Apr 24, 2010

SOURCE: tool to remove front brake caliper to replace rotor Escape 2005

You need a 7mm socket, which are available at auto parts stores.

RON HOOPER

  • 23 Answers
  • Posted on May 08, 2010

SOURCE: stuck calipers

Brake lines are not releasing fluid back to master cylinder. Open bleeder and see if wheel will turn. If it does replace brake line to caliper

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(rotor is smooth looking on the inner and outer face. they are not rusted and pitted. or gouged) pad has brake materiel of at least 1/8". if that looks ok then remove the caliper and look at the parking brake shoes and hardware. i see a lot of the shoes brake material comes loose from the backing. which will cause noise, vibration, sometimes wheel lock up.

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Diagram for parking brake cables

Removal & Installation
  1. For the 1500HD, relieve the tension from the park brake cable by pulling down on the park brake cable in front of the equalizer then removing the cable from the equalizer bar.
  2. For the 25/35 series Disable the park brake cable automatic adjuster.
  3. Raise and safely support the vehicle.
  4. Remove the tire and the wheel.
  5. Perform the following procedure to remove the cable (2) from the backing plate (4):
    • Compress the spring (3) by pushing toward the lever (1).
    • Depress the locking tabs.
    • Pull the cable housing out of the backing plate (4).
    • Remove the cable (2) through the slot in the backing plate.
      32085_silv_g0069.gif

      Lever (1), cable (2), spring (3) and backing plate (4)

  6. Remove the park brake cable (2) from the lever (1).
  7. Remove the rotor.
  8. Remove the rear axle shaft.
  9. Remove the park brake shoe return spring (6).
    32085_silv_g0070.gif

    Park brake shoe assembly 1500HD, 25 and 35 Series
    Click to Enlarge

  10. Remove the park brake shoe anchor springs and pins.
  11. Separate the tips of the shoes from the park brake actuator and remove the park brake shoes and adjuster assembly from the vehicle.

To install:

  1. Clean the debris and the dust from the park brake components using a clean shop cloth.
  2. Install the adjuster assembly to the park brake shoes.
  3. Separate the tips of the shoes and install the park brake shoes to the park brake actuator.
  4. Install the park brake shoe anchor springs and pins.
  5. Install the park brake shoe return spring (6).
  6. Adjust the park brake shoe.
  7. Install the rear axle shaft.
  8. Install the rotor.
  9. Install the park brake cable (2) to the lever (1).
  10. Perform the following procedure to install the cable (2) to the backing plate (4):
    • Compress the spring (3) by pushing towards the lever (1).
    • Route the cable (2) through the slot in the backing plate.
    • Push the cable housing into the backing plate (4) until the locking tabs snap into place.
  11. Install the tire and wheel.
  12. Remove the safety stands.
  13. Lower the vehicle.
  14. Enable the park brake cable automatic adjuster.
  15. For the 1500HD, install the park brake cable to the equalizer by pulling down on the park brake cable in front of the equalizer then installing the cable to the equalizer bar.
  16. Adjust the park brake cable.
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Rear DRUM instructions are first If you would Like Pictures and all They Must Be Emailed as TOO LARGE For FixYa's Format im at aol.com
Just use my Knickname@ and let me know where to send.


  1. Raise and support rear of vehicle, then remove wheel and tire assembly.
  2. Remove brake drum. If brake drum cannot be removed easily, insert a suitable screwdriver through hole in backing plate, then push adjuster lever away from adjuster and back of adjustment tension.
  3. Remove tension spring, using a suitable tool, then remove rear shoe hold-down spring and pin. Remove rear brake shoe and anchor spring, Fig. 7.
    1. On Land Cruiser models, remove front hold-down spring using a suitable tool, then disconnect the parking brake cable from the parking brake bellcrank, Fig. 7.
    2. On Pickup, 4Runner, 4WD T100 and 4WD Tacoma models, remove front shoe hold-down spring and pin, using a suitable tool, then disconnect No. 1 parking brake cable from No. 3 parking brake bellcrank.
    3. On 2WD T100 models, proceed as follows:
      1. Remove E-ring, then automatic adjusting lever and C-washer, then parking brake lever. Disconnect brake line from wheel cylinder using a suitable container to catch fluid.
      2. Remove wheel cylinder. Remove following parts from wheel cylinder: two boots, two pistons, two pistons cups and spring.
    1. On models except 2WD T100, remove front brake with strut, then disconnect parking brake cable from front shoe. Remove parking brake cable No. 2.
    2. Remove adjusting lever spring, then the adjuster from front shoe.
    Inspection
    1. Measure brake drum inside diameter. Inside diameter should be 11.61 inches,
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      2. Inspect brake lining and drum for proper contact and replace drum or shoes as necessary.
      3. Inspect wheel cylinder for corrosion or damage.
      4. Inspect backing plate for wear or damage.
      5. Inspect bellcrank components for bending, wear or damage.
      6. Apply a suitable lubricant to backing plate contact areas.
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      1. On 2WD T100 models, proceed as follows:
        1. Apply lithium soap base glycol grease to piston cups, pistons and boots.
        2. Assemble and install wheel cylinder.
        3. Connect brake line to cylinder.
      1. Apply high temperature grease to following parts:
      1. Apply a suitable lubricant to adjuster bolt threads and end.
      2. Assemble adjuster to lever, then install adjuster lever spring.
      3. On Land Cruiser models, install parking brake lever cable to parking brake shoe, then attach cable to bellcrank.
      4. On Pickup, 4Runner, 4WD T100 and 4WD Tacoma models, install No. 1 parking brake cable to parking brake lever shoe, then attach the other side of cable to No. 3 bellcrank.
      5. Position front shoe in place with end of shoe inserted into piston, then install shoe hold-down spring and pin using a suitable tool.
      6. Assemble anchor spring to front and rear shoe, then install rear shoe with end inserted in piston.
      7. Install rear shoe hold-down spring and pin, then the tension spring.
      8. If necessary, adjust bellcrank as follows:
        1. Lightly pull bellcrank in direction "A", Fig. 8, until there is no slack in part "B".
            1. Rotate adjusting bolt until dimension "C" is .016-.031 inch.
            2. Lock adjusting bolt with locknut, when connect parking brake cable to bellcrank.
            3. Install tension spring.
          1. Ensure proper parking brake travel.
          2. Pull adjusting lever cable upward, then release and ensure adjusting bolt rotates. If bolt does not rotate, check for improper installation of rear brakes.
          3. Adjust strut to shortest possible length, then install drum.
          4. Pull parking brake lever fully upward. Repeat process several times.
            1. Remove drum, then check for proper clearance, Fig. 4. Clearance should be .024 inch. If clearance is not as specified, check parking brake system.
            2. Install brake drum, then bleed and refill brake system.
            3. Install wheel and tire assembly, then lower vehicle.

FRONT ROTORS & PADS
  1. Remove caliper.
  2. Remove cap and snap ring, Fig. 10, then remove cone washers with tapered punch.
  3. Insert suitable length bolts into flange bolt holes, then tighten bolts evenly and remove flanges.
  4. Remove free wheel hub cover and snap ring, then remove nut, spring washer and cone washer with suitable tapered punch.
  5. Remove free wheel hub body and gasket.
  6. Remove locknut, lock washer and adjusting nut.
  7. Remove axle hub and brake disc as an assembly.
  8. Remove oil seal and inner bearing from hub.
  9. Reverse procedure to install. Torque adjusting nut to 43 ft. lbs., then back off nut. Torque nut to 18 ft. lbs. Using spring scale attached to hub bolt, check that preload is 1.4-12.6. Install lockwasher and locknut, if equipped. Torque locknut to 35 ft. lbs., and recheck preload. Secure lockwasher by bending one tab inward and one tab outward.
  1. Raise and support front of vehicle, then remove tire and wheel assembly.
  2. Remove clip and hole pins, Fig. 9.
  3. Remove anti-rattle spring and shim(s) if equipped, then remove brake pads.
  4. Lubricate caliper housing with suitable brake grease at pad contact points.
  5. Reverse procedure to install.
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You can't remove the rotors because the emergency brake is tight on the inside of the rotors. Make sure it's not engaged when you are working on the rear brakes. Block the front tires for saftey. Then you have to remove the rear calipers from the mounting brackets, there are two bolts that hold the calipers on. Make sure you hang the calipers securily with some wire so you don't damage the rubber brake line hose. Then you need to adjust the emergency parking brake shoes in order to remove the rotors. Theres a rubber plug on the backside of the rear hubs, once you look at the back of the hub you'll see the plug. It's on the top. Once you take out the plug, you need to use a screw driver to turn the star spindel. You need to turn the star spindel counter-clockwise in order to give yourself enough clearance to remove the rotors. The beauty of this design is that ford incorporated a drum and caliper system together, but it's difficult to take off the rotors if the emergency brake shoes are to tight. The inside of the rotors acts as the drums for the emergency brake system. I've done this and it's not that hard, but, I did have to replace the emergency brake shoes because they were worn out and the shoes fell off the metal backing plates when I finally got the rotors to come off. They only glued these shoes onto the backing plates, they don't rivet them so take your time getting the rotors off or you can damage the emergency brake shoes, but if you do they are cheap at napa. My service guide says to install the new rotors, use a couple of lug nuts to hold it on, then adjust the star spindal for the emergency brake all the way clockwise until you can't turn it anymore, then you must back it off 8 clicks counter-clockwise. Make sure the emergency brake is not engaged when you are doing this, the 8 clicks backwards compensates for when you do engage the parking brake because the shoes expands outwards. This adjustment sets the emergency brakes so they work properly. Once the emergency brake is properly set you can't remove the rear rotors, which is what your initial problem is. Then install the rubber plug back in the hole, put on the new pads and calipers and you're good to go.
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