Factory Big Brake Kit

hmmm

GREAT idea ! And THANKS for serving !!!

I did a little digging also, what I noticed is that the ball joint part numbers seem to be different than the F150. It is likely the spindles are different. Ideally I would like to get the larger rotors WITH ABS exciter rings and convert mine to 4WABS at the same time as the brake conversion. I'm gonna go pull my rotor/spindle/caliper a apart right now and do some peeking.

Problem with my vehicle is the donor parts I used for my 2wd conversion are from a 1995 F150 2wd Rear ABS only truck. I will take pics of my stuff when I have it off.

In the mean time here is a little footwork I did so far.

The 12.83" inch rotor fits all 2004-2007 E150 uses 1/2" studs with .60" shank

E150Rotor.jpg


1996 F150 Caliper & Rotor
FORDE-150 ECONOLINE(1994 - 2003)
FORDE-150 ECONOLINE CLUB WAGON(1994 - 1998)
FORDF-150(1994 - 1996)
FORDF-150 LIGHTNING(1994 - 1995)
FORDF-150 SUPER CAB(1994 - 1996)

Brake Hose 4WABS Dorman H380323 / H380324
FORDE-150 ECONOLINE(1994 - 2004)

Ball Joint
Upper FORD E-150/E-350 ECONOLINE(1992 - 2002) F150 1987-1996
Says E-150 1992-2008 on MOOG Part K80196
Lower MOOG Part # K8611T FORD E-150 ECONOLINE(1992 - 2004)

Caliper for 2004 E-150 RAYBESTOS Part # RC11793 Right
FORD E-150(2004 - 2007)

Rotor with 4WABS
Raybestos 680320 Advanced Technology; 12.83" / 5 Bolts
Front; Contains ABS Exciter Ring FORD E-150(2004 - 2007)

Caster/Camber Bushing Fits only 1992-2008 E-150

2004 Front Outer Wheel Bearing SKF BR12 Same as early F150
2004 Front Inner Wheel Bearing SKF BR13 Same as early F150
Front Inner Wheel Seal National 4148 Same as early F150
FORDE-100 ECONOLINE(1968 - 1983) FORDE-100 ECONOLINE CLUB WAGON(1968 - 1982)
FORDE-150 ECONOLINE(1975 - 2004) FORDE-150 ECONOLINE CLUB WAGON(1975 - 1998)
FORDE-150 ECONOLINE SUPER(1977 - 1991)FORDE-150 ECONOLINE SUPER WAGON(1978 - 1982)
FORD EXPEDITION(1997 - 2002) FORDF-100(1965 - 1983)
FORDF-100 SUPER CAB(1977 - 1979) FORDF-150(1975 - 2003)
FORDF-150 HARLEY-DAVIDSON EDITION(2001 - 2003)FORDF-150 HERITAGE 2004
FORDF-150 LIGHTNING(1993 - 2004) FORDF-150 SUPER CAB(1977 - 1998)
FORDF-250(1965 - 1999) FORDF-250 SUPER CAB(1977 - 1999)
LINCOLN BLACKWOOD 2002 LINCOLN NAVIGATOR(1998 - 2002)

FrontBrakes.jpg

FrontBrakes1.jpg

FrontBrakes2.jpg

FrontBrakes3.jpg

FrontBrakes4.jpg

FrontBrakes5.jpg

FrontBrakes6.jpg

FrontBrakes7.jpg
 
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1995 Spindles won't work with bigger rotors

As you can see in the last thread with pictures, the spindles are cast and wrap around the rotor and hold the pads in place. If the 2004 E150 will fit in our I-Beams I think it will be a great conversion. Otherwise, I don't see how to make the bigger calipers and rotors fit on the older spindles.
 
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No luck today boys!! Found one 05' van and the wheels, rotors and all were gone off the front. (as well as most of the front due to an accident)My local yard doesn't seem to have very much stuff after 2000 model year. I will be checking back frequently over the next couple weeks to see what I can find. I will not forget about this one and I will let you all know what's going on.:(
 
stroked93' said:
No luck today boys!! Found one 05' van and the wheels, rotors and all were gone off the front. (as well as most of the front due to an accident)My local yard doesn't seem to have very much stuff after 2000 model year. I will be checking back frequently over the next couple weeks to see what I can find. I will not forget about this one and I will let you all know what's going on.:(
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Did you happen to check the rearend and see if it is in fact rear disc with an 8.8"
 
drvovru said:
Did you happen to check the rearend and see if it is in fact rear disc with an 8.8"
Click to expand...

No sorry, I was all disappointed about not finding anything and I forgot all about the rear brakes until I was at the coffee shop afterwards. I have some time off work the week after Christmas and i am planning on checking out some other pull yer own yards. I will check then and let you all know.
 
I believe the caliper mounts on the new one holds the pads and caliper in place if so you could trim off the stock pad holders and bolt the new one on I too am going to try this but, I had to order the caliper and bracket, so we will see. has anybody else done airbags on the front of an L yet I was thinking about it.
 
drvovru said:
As you can see in the last thread with pictures, the spindles are cast and wrap around the rotor and hold the pads in place. If the 2004 E150 will fit in our I-Beams I think it will be a great conversion. Otherwise, I don't see how to make the bigger calipers and rotors fit on the older spindles.
Click to expand...

In 2003 the E150 had the same caliper....exact same and the same size rotor but it had the abs tone ring. One year later it had a bigger rotor, 1.1" bigger and a bigger caliper but the kicker is it uses a bracket to locate it about a half inch further away from the original location and the bracket bolts to where the 2003 caliper bolted to.

Damn...just looked at pictures again...why can't they just make a regular caliper

I looked at the picture of the caliper and the pads are held in place by the caliper bracket itself. ...maybe the spindle is used for the E250's too or even the E350 and those models have different calipers.
 
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86f150302 said:
MUST HAVE MORE INFO ON AIRBAGSSSS PLEASEEE! :heart:
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That looks like a custom setup. The only company that makes a kit for our trucks is AIM Industries/Chassis Tech or what ever they call themselves these days. Mine is completely handmade.
I'm curious how much travel that small bag gives.
 
Sportruk said:
That looks like a custom setup. The only company that makes a kit for our trucks is AIM Industries/Chassis Tech or what ever they call themselves these days. Mine is completely handmade.
I'm curious how much travel that small bag gives.
Click to expand...


I know there isn't a kit. Ive just always been told it will be alot of work to run bags. But it looks like the springs were just replaced with bags in the pics(I know its not that simple)

I just dont need a crazy slammed lay frame setup. I just want to get nice and low and be adjustable plus having a better ride..

I love your setup Sportruk. You can come do mine if you want to ;)
 
thread jacking?

Sportruk said:
I'm curious how much travel that small bag gives.
Click to expand...

Geez guys, I wasn't trying to turn this into a Airbag thread... But thanks for noticing. :tongue:

Yes they have only about 5" of travel they are Air House II bags by Universal Suspension. I had to hand build the kit myself, it was a PITA ! :no:

I am going to rip it all out here in a few weeks and put in larger bags, it rides really rough. I think the air bladder size is the problem. The needle jumps 10-25 psi over bumps, rear bag needle only jumps 2-10 psi.

I would like it to slam a little lower but we are limited by the tire hitting the inner fenderwells.

BroncoLkSam.jpg


OK>>>>>>>>>>>>> Back on topic.

I personally looked at a 2004 E150 tonight. VIN# 1FTRE14L74HA76115 with a 5.4L
It does have 4WABS, it does have Dual-Piston calipers, it does have COMPLETELY different spindles. So the only way I see this working is a complete spindle swap.

On a seperate note, the rearend end is a 9.75" with a VSS sensor on ring gear, REAR-DISC, 3.55 gears, NON Trac-Loc and our correct 5-5.5 (5-139.7mm) bolt pattern with 1/2" Acorn lug nuts, and it uses 16" wheels. I was unable to get the hub-hub width or the spring pad spacing.

I am gonna run to the parts store and compare the lower ball joints and see what is different between ours 1993-1996 and 2004.

YES !!!! I took pics of the van >>>>>>>>> No you can't see them until later when i get back from the parts store. :D:D:D
 
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I was looking at the ball joint part numbers and they are different. It's going to be a case of having both spindles in hand and measure everything, including placement and dimensions of the steering arm portion of the spindle.
 
I don't imagine the spindles are going to bolt on in place of our spindles. I'd just really like to know if the bracket will bolt to the 94 or 95 spindle. I believe that casting that the E150's use are very old and that's why they have what looks like the brake pad holding tabs casted onto it. Looking at the caliper with the bracket on it I see that the bracket it self holds the pads from moving. I also don't see the rotors not bolting onto our spindle because they had the same rotor essentially. If they share the same bearings and such there's a good chance that they will just mount right up.
 
Alrighty ladies and gentlemen, I have spent a good 6 hours on this issue today after looking at a 2004 E150 in person. I took a few measurements and compared my parts to it, I am 95% confident this will be a good conversion.

You will need a 2004 ONLY E150 for donor parts, you will need the entire spindle/rotor/caliper and brake lines. You will need to press out the lower ball joint ONLY and replace with an early lower ball joint. (See below pictures)

These pics should answer a lot of questions.

04E150_Front.jpg


04E150_Front1.jpg


04E150_Front2.jpg


04E150_Front3.jpg


04E150_Front4.jpg


04E150_Front9.jpg


The only difference between the upper ball joints is the supplied clamping bolt. Other than that, the ball joint itself is the same.

BallJoints.jpg


BallJoints1.jpg


The lower ball joints are quite different with the exception of the dimensions of where it presses into the spindle, that is identical. Thus, you can swap old style lower ball joints into 2004 spindles.
BallJoints2.jpg


I will start a separate thread for discussion about the rearend conversion.
 
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I'm glad someone is actually running with my idea, it's sucked not really having the drive to pursue this and now that I do I'm deployed.

My favorite part of this whole conversion though is we'll actually have bigger brakes up front compared to the Gen 2 guys...stock Gen 1 (11.71) stock Gen 2 (12.13) Gen 1 with E150 Brakes (12.83) but with the rear disc conversion we'll be at (13.03) and the Gen 2 (13.13)

It should be noted now that I don't see any of these conversions working with 15" wheels
 
jwbronco said:
I'm glad someone is actually running with my idea, it's sucked not really having the drive to pursue this and now that I do I'm deployed.
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Glad I could help you rest a little easier, it sucks having ideas roll around in your head and you can't get closure.

My favorite part of this whole conversion though is we'll actually have bigger brakes up front compared to the Gen 2 guys...stock Gen 1 (11.71) stock Gen 2 (12.13) Gen 1 with E150 Brakes (12.83) but with the rear disc conversion we'll be at (13.03) and the Gen 2 (13.13)
Click to expand...

Here is a link to the rearend thread;

http://www.nloc.net/vbforum/gen-1-lightnings/210336-9-75-rearend-upgrade-post1956890.html#post1956890


It should be noted now that I don't see any of these conversions working with 15" wheels
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Yes, the E150 has 16" steel wheels. Most of us are already running 17" so it shouldn't be too big of a deal.
 
One other thing to think about, does anyone know if the stock master cylinder would supply enough pressure for the new calipers?
 
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