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Home >> Ford Truck >> 1993 >> F 350 4WD Pickup V8-460 7.5L >> Repair and Diagnosis >> Brakes and Traction Control >> Parking Brake System >> Service and Repair >> Disassembly and Assembly

Disassembly and Assembly




Transmission Mounted Parking Brake Disassembly


1. Remove the parking brake assembly.

Transmission Mounted Parking Brake Disassembly And Assembly:






2. Using Tool T7OT-4252-D or equivalent, mount parking brake assembly in vise, using brass jaw protectors to prevent damage. Remove the 65mm hex locknut from the mainshaft.

Transmission Mounted Parking Brake Disassembly And Assembly:






3. Using a 3-jaw puller, Tool D8OL-1013-A or a suitable press, remove the mainshaft, brake drum and output flange out of the case assembly.

4. Using puller D8OL-1002-L with bearing cone remover D79L-4621-A and step plate D8OL-630-6, remove the inner bearing cone from the mainshaft.

5. Remove the output shaft and brake assembly from the vise. Turn the shaft assembly over and put the threaded end in the vise. Be sure to use soft jaw inserts to protect the mainshaft.

Transmission Mounted Parking Brake Disassembly And Assembly:






6. Remove the four hex nuts attaching the flange and brake drum to the output shaft. Remove the drum and flange from the output shaft.

NOTE: The drum, yoke/flange, and mainshaft are balanced as a unit, and must be marked to make sure that they are assembled in the same position. Leave the bolts in the output flange. Total assembly must be disassembled.

7. Remove the input shaft oil seal, spacer, O-ring, bearing cone assembly and bearing cup from the input shaft end of the case using tool number T77F-1102-A or equivalent.

Transmission Mounted Parking Brake Disassembly And Assembly:






8. Remove the four bolts attaching the splash shield and brake assembly to the case. Remove the brake assembly and splash shield from the case.

9. Remove the brake actuating lever and the lever spring from the case.

NOTE: For brake assembly component repair, refer to brake component repair in this section.

Transmission Mounted Parking Brake Disassembly And Assembly:






10. Using tool T77F-1 102-A remove the outer bearing cup.

11. Unscrew and remove the vent from the case.

Brake Shoe Disassembly

1. Holding the brake assembly securely, remove the two brake shoe return springs using a suitable brake spring tool.

2. Spread the free ends of the brake shoes apart and remove the brake shoes from the lower anchor pin. Remove the shoe-to-shoe spring.

Transmission Mounted Parking Brake Shoe Disassembly And Assembly:






3. Clean any grease or contamination from the support plate. Remove contamination from the shoe guide jugs and other shoe bearing surfaces with sand paper.

4. Coat the following areas with Ford Disc Brake Caliper Slide Grease D7AZ-19590-A (ESA-M1C172-A). Use only a light application of grease at these points.

- Camshaft lugs and ball of actuating lever.

- Shoe guide lugs and shoe bearing points of the support plate assembly.

- Upper and lower anchor pins.

- Anchor pin contact points of the brake shoes.

Brake Shoe Assembly

1. Using new brake shoe and lining assemblies, install new Shoe-to-shoe springs into the lower holes of the brake shoes.

2. Spread the opposite ends of the shoes and assemble the lower ends of the shoes over the shoulder of the lower anchor pin, twisting the sh6es into position. Move the upper ends of the shoes to the upper anchor pin, inserting the shoe webs between the shoe guide jugs. and the bearing surfaces of the support plate.

Transmission Mounted Parking Brake Shoe Disassembly And Assembly:






3. With the upper ends of the shoes against the upper anchor pin, install two new shoe return springs. Install the short hooked end of each spring into the upper holes of the brake shoes and hook the opposite end of each spring over the anchor pin nib, using a suitable spring installation tool. Be sure the open end of the spring hook faces toward the brake centerline.

Transmission Mounted Parking Brake Assembly

1. Press the plug into the output flange if plug was previously removed. Apply sealer to the lip of the plug. Press into place with the lip of the plug facing outward. The plug must be flush with the edge of the bore.

2. Turn the case over and install the outer bearing cup into the case. Press in using Bearing Cup Replacer TB8T-2598-E (or equivalent) until the bearing cup bottoms in the bore.

Transmission Mounted Parking Brake Disassembly And Assembly:






3. Install the inner bearing cone assembly into the cup.

Transmission Mounted Parking Brake Disassembly And Assembly:






4. Apply a light coating of sealer to the outer edge of the outer oil seal. Position the oil seal in the bore of the case with the sealing lip facing inward. Press the seal into the bore of the case using Seal Replacer T88T-2598-C or equivalent. Press the seal in flush with the bore surface.

Transmission Mounted Parking Brake Disassembly And Assembly:






5. Install the actuating lever spring in the boss in the case.

Transmission Mounted Parking Brake Disassembly And Assembly:






6. Apply a light coating of Ford Disc Brake Caliper Slide Grease D7AZ- 19590-A (ESA-M1C172-A), or equivalent to the ball of the actuating lever. Install the lever (ball end) into the hole in the boss of the case, through the coiled end of the spring.

7. Position the backing plate and brake assembly into position on the case. Insert the actuating lever (cam end) into position in the brake assembly.

Transmission Mounted Parking Brake Disassembly And Assembly:






8. Attach the brake assembly and backing plate to the case with four hex head bolts. Tighten the bolts to 118-123 N.m (87-91 ft-lb). Attach retracting spring to the actuating lever while bending the long end to snap over the lever.

9. Place the mainshaft in a vise with the flanged end up. Protect the shaft with soft jaw inserts.

10. Install the brake drum and output flange onto the flange end of the mainshaft.

Transmission Mounted Parking Brake Disassembly And Assembly:






11. Install the output flange onto the brake drum, aligning the marks made during disassembly (to make sure that the balance is not disturbed). Install the tour hex nuts and tighten to 113-117 N.m (83-87 ft-lb).

12. Remove the mainshaft with drum assembly from the vise. Turn the unit over and clamp it securely in the vise.

Transmission Mounted Parking Brake Disassembly And Assembly:






13. Install the case onto the mainshaft guiding the shaft through the oil seal and bearing cone.

14. Using Bearing Cone Replacer T88T-2598-F or equivalent, seat the output bearing onto the mainshaft.

15. Install the input bearing cup into the housing using Bearing Cup Replacer T88T-2598-D or equivalent.

Transmission Mounted Parking Brake Disassembly And Assembly:






16. Install the shim on the mainshaft.

NOTE: This shim determines mainshaft end play, and it is available in thicknesses in variances of 0.0019 inches.

17. Install the inner bearing cone onto the mainshaft.

In order to measure mainshaft end play, install the bearing spacer without the O-ring onto the mainshaft.

Transmission Mounted Parking Brake Disassembly And Assembly:






18. With the case assembly and mainshaft clamped firmly in the vise, screw the hex locknut onto the mainshaft. Tighten the nut to 288-293 Nm (212-216 ft-lb) using 65mm Locknut Wrench T7OT-4252-D or equivalent.

Transmission Mounted Parking Brake Disassembly And Assembly:







19. Mount a dial indicator between the mainshaft and the case to check end play. Use dial indicator with bracketry TOOL-4201-C or equivalent.

20. While rotating the case assembly on the mainshaft to center the bearings. Apply pressure up and down while taking an end play reading. A reading of 0.0483-0.0991 mm (0.0019-0.0039 inches) is required. If the reading is not to specification, a thicker or thinner shim must be used.

21. Remove the locknut and the bearing spacer from the shaft.

22. If required, remove the inner bearing cone and add the necessary additional shims to obtain the specified end play.

23. Reinstall the inner bearing cone on the shaft.

Transmission Mounted Parking Brake Disassembly And Assembly:






24. Coat the outer shell of a new input oil seal with sealer and install it in the bore of the case until it seats inside the bore. The sealing lip of the seal must face inward.

Transmission Mounted Parking Brake Disassembly And Assembly:






25. Install a new O-ring in the notch of the bearing spacer and install both parts onto the mainshaft until the spacer butts against the shoulder of the input bearing.

Transmission Mounted Parking Brake Disassembly And Assembly:






26. Install a new locknut on the shaft, and tighten to 288-292 Nm (212-216 ft-lb).

27. Upset the outer lip of the locknut into the slot in the shaft, using 65mm Locknut Wrench T7OT-4252-D or equivalent.

28. Screw the vent into the case, and tighten it to 11-16 N.m (8-12 ft-lb).

29. Remove the parking brake assembly from the vise.

30. With the parking brake in the as installed position, fill the case with Motorcraft MERCON Multi-Purpose Automatic Transmission Fluid, XT-2QDX or DDXE4AZ-19582-B (ESP-M2C166-H) or equivalent through the filler hole. Fill to the bottom of the filler hole, and install and tighten the fill plug to 35-40 N.m (25-30 ft-lb).

31. Reinstall the parking brake assembly as outlined in this section.
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