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replace both calipers and bleed system. remove wheel, unbolt brake flex hose where it mounts to the caliper,clamping hose to keep from losing brake fluid, unbolt caliper from caliper mounting bracket. and remove caliper. re-install in reverse order bleeding front brakes making sure master cylinder doesn`t run out of brake fluid.
Section 06-03: Brakes, Front Disc
1996 F-150, F-250, F-350 4x2, 4x4, Bronco and F-Super Duty Vehicles Workshop Manual
REMOVAL AND INSTALLATION
Heavy-Duty Rail Slider, F-Super Duty
Replace brake shoe and lining (2001) as follows when the lining is worn to a minimum thickness of 0.794mm (1/32 inch) above the front disc brake rotor shield.
CAUTION: Always replace all brake shoes and linings on an axle. Never replace only one wheel (1007). Removal
To avoid fluid overflow when the caliper pistons are pressed into the caliper cylinder bores, siphon or dip part of the brake fluid out of the brake master cylinder reservoir (2K478). Discard the removed fluid.
Raise the vehicle and install safety stands. Remove the front wheel and tire assembly.
Place an appropriate size C-clamp on the disc brake caliper with end of clamp against caliper and end of screw against outer shoe. Tighten the clamp to bottom the caliper pistons in the cylinder bores. Remove the clamp. Do not use a screwdriver or similar tool to pry caliper pistons (2196) away from the front disc brake rotor (1125).
Clean excess dirt from area around pin tabs.
Tap upper caliper pin toward inboard side until pin tabs touch the front wheel spindle.
Using Hydraulic Caliper Pin Remover D89T-2196-A or equivalent and a light hammer, drive the pin from the disc brake caliper as follows:
Position the notched end of the tool against the caliper pin (retention tab half), at a 45-degree angle from the pin retention tabs.
Tap the tool with the hammer to compress the retention tabs.
As the retention tabs are compressed, move the tool to gain a straight approach to the caliper pin, and continue tapping to drive the caliper pin through the caliper/spindle groove.
Repeat removal procedure for lower caliper pin.
CAUTION: Do not let the disc brake caliper hang by the front brake hose (2078). The front brake hose could become stretched or twisted which can cause the front brake hose to leak and rupture, resulting in failure.
Remove the disc brake caliper from the front disc brake rotor. If the disc brake caliper is to be removed for service, remove the front brake hose from the disc brake caliper. Plug the end of the front brake hose to prevent fluid loss and entry of air into the system. If the disc brake caliper is not to be removed, wire it up to the frame of the vehicle to avoid damage to the front brake hose.
Installation CAUTION: Always replace all brake shoes and linings on an axle. Never replace only one wheel.
NOTE: There is a raised section at one end of each shoe so installation can be made in one direction only.
Install new inner and outer lining.
Lubricate the knuckle upper and lower inner pad grooves and caliper grooves with Disc Brake Caliper Slide Grease, Silicone Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A. Install the disc brake caliper on a front wheel spindle, making sure the mounting surfaces are free of dirt.
CAUTION: Do not allow the tabs of the caliper pin to be tapped too far into the spindle groove. If this happens it will be necessary to tap the other end of the caliper pin until the tabs snap into place. The tabs on each end of the caliper pin must be free to catch on the spindle flanks.
Position caliper pin with the pin retention tabs oriented adjacent to the spindle groove.
Tap the caliper pin on the outboard end with a hammer. Continue tapping the caliper pin inward until the retention tabs on the sides of the caliper pin contact the spindle face. Repeat procedure for the lower caliper pin.
this could be caused by a few things, first you need to jack the truck up you will need all 4 wheels off the ground, put the transmission in neutral and have some one get in the truck and wile turning each wheel have the person in the truck push the brake pedal the wheel should stop instantly then have the person release the brake the brake should release instantly,( do this to each wheel ) if all brakes remain locked ( wont release instantly ) then replace the master cylinder if the both rear brakes wont release instantly replace the brake hose from the frame to the rear differential, if the both front brakes wont release replace master cylinder, if only one front brake wont release open the bleeder on that brake caliper if the wheel releases replace the caliper hose if the brake still wont release with the bleeder open replace the caliper, you should replace the caliper and brake hoses as a pair.
Hello: You nare going to have to replace/rebuild front calipers, replace Both rubber hoses that go fron the frame to the calipers. You may have to replace the rubber hoses in the rear and the rear wheel cylinders. Contaminated brake fluid creates a expensive and long repair.
check for front brake calipersdragging, if the are replace calipers and front brake hoses, if calipers ok replace master cylinder, This is how to check calipers, jack up front of truck have some one apply brakes and release as soon as they release the brake peddle the wheels should spin freely if not brake the brake line lose at master cylinder if wheels spin free with line loose replace master cylinder, if not replace calipers and hoses.....HOPE THIS HELPS
Section 04-01: Suspension and Wheel Hubs, Front
1996 Taurus, Sable Workshop Manual
REMOVAL AND INSTALLATION
Wheel Hub Bolt
Raise vehicle on hoist.
Remove wheel and tire assembly. Refer to Section 04-04 .
Remove disc brake caliper (2B120), and front disc brake rotor (1125). Refer to Section 06-03 .
Brake Shoe and Lining
Remove brake master cylinder filler cap (2162). Check fluid level in brake master cylinder reservoir (2K478). Remove brake fluid until brake master cylinder reservoir is half full. Discard removed fluid.
Raise vehicle on hoist. Refer to Section 00-02 .
Remove wheel and tire assembly from front disc brake rotor mounting face. Use care to avoid damage or interference with disc brake caliper (2B120), front disc brake rotor shield (2K004) or front wheel knuckle (3K185).
Remove rear brake pin retainers (2N386). ( I think it is a T 40 torx bit you need)
NOTE: It is not necessary to disconnect hydraulic connections.
Lift disc brake caliper from front disc brake caliper anchor plate (2B292) and front disc brake rotor (1125). Do not pry directly against metal caliper piston or damage will occur.
Position disc brake caliper out of the way and support with wire to avoid damaging the disc brake caliper and front brake hose (2078).
Remove outer brake shoe and lining (2001) assembly from front disc brake caliper anchor plate.
Remove inner brake shoe and lining assembly.
Position lug bolt (1107) to clear front wheel knuckle (3K185).
Remove lug bolt from wheel hub (1104).
Install lug bolt into wheel hub.
Using a lug nut (1012), seat wheel hub bolt into wheel hub.
Install front disc brake rotor and disc brake caliper. Refer to Section 06-03 .
Install wheel and tire assembly. Tighten lug nut to 115-142Nm (85-104 lb-ft).
Start from right rear, then, left rear, right front, left front. Fill master cylinder. Have helper sit in car, have helper hold brake pedal down. open bleed screw. fluid and air comes out. close screw. release brake pedal. Continue until no air comes out. Move to next wheel. Keep an eye on master cylinder fluid level after each wheel.