How to Repair Ford Dually Brakes


Brakes on a Ford dually F250, F350 or F450 are often worked much harder than brakes on a standard pickup. Most dually owners use the trucks for pulling fifth wheel trailers, loading the beds down with heavy payloads or pulling hitched trailers. All that extra weight means the brakes have to work harder in order to bring the rig to a halt safely. This also translates to more frequent brake repairs than the same driver would experience in a lighter-duty vehicle.

Things You'll Need

  • Wheel chocks (4)
  • Safety glasses
  • Lug wrench
  • Jack
  • Jack stands
  • Brake cleaner
  • Drip pan
  • Socket set
  • White lithium grease
  • Caliper piston tool (optional)
  • Torque wrench (optional)
  • Sandpaper (optional)
  • Put a wheel chock in the front and rear of both of the front tires so the truck can't roll away.

  • Put on your safety glasses and loosen the rear lug nuts, but do not take them off yet.

  • Jack the rear of the truck up then place a jack stand under the rear axle on either side.

  • Remove the lug nuts and set them aside, then pull the wheels off.

  • Put the drip pan under the brake assembly and then spray down the brake caliper and disc thoroughly with brake cleaner.

  • Use the socket wrench to remove the caliper bolts holding the brake caliper to the hub.

  • Slide the caliper up and away from the disc, then remove the pad retaining clip and pull the old pads out.

  • Remove the rotors and have them machined, or replace them at this time if at all possible. If neither option is available, take some sandpaper and score the rotor face in a circular motion to remove the sheen from the old pads.

  • Insert the new pads into the caliper and put the retaining clip back on in the reverse order of how you removed it. You may need to apply up to 100 foot-pounds of force to the caliper pistons to get them to retract far enough to put the new pads in. If you cannot get them back in, you will need to get a caliper piston tool to do the job.

  • Clean the caliper slides with brake cleaner and then apply white lithium grease to them. This ensures the caliper can slide in and out freely when you apply the brakes.

  • Slide the caliper back over the disc and reinstall the caliper bolts.

  • Put the wheels back on, being careful to put them on in the proper order so you do not have a dirty, dull inner wheel on the outside while your shiny clean one is on the inside. Reinstall the lug nuts and tighten.

  • Jack the back end off the jack stands, remove the stands and then lower the truck onto the ground.

  • Tighten the lug nuts on both sides with a torque wrench to the proper torque specifications based on your wheels and lug nuts. If you are uncertain what that specification is, call a local tire shop and they can tell you. If you do not have a torque wrench, drive to a tire shop or your local Ford dealer and have them torque the lugs nuts down for you immediately.

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