E150 4 Wheel Disc Brake Conversion
Cargo Master
Joined: Apr 2013
Posts: 3,087
Likes: 25
From: Central Florida
I've been watching and waiting for you to get it together and then have difficult issues like rears locking up or not working much at all, or vice-versa with the fronts.
Or maybe a crash or near miss during the initial test drive.
Or maybe a crash or near miss during the initial test drive.
Thread Starter
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Senior User
Joined: Jan 2011
Posts: 487
Likes: 2
From: Chicago
How nice of you to have such faith in me.
Cargo Master
Joined: Apr 2013
Posts: 3,087
Likes: 25
From: Central Florida
i have plenty of faith in your work. I've seen your pictures and I think anyone who cleans and paints old brakes parts is probably very capable in assembling them. I just think the brake systems are a little more complicated than you do.
Master cylinder internals, proportioning valve, ABS unit ... maybe more.
I hope all goes well for you, and obviously I'm joking about damage to your truck/people.
I just think the brake systems are a little more complicated than you do.
Master cylinder internals, proportioning valve, ABS unit ... maybe more.
I hope all goes well for you, and obviously I'm joking about damage to your truck/people.
I just think the brake systems are a little more complicated than you do.
Thread Starter
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Senior User
Joined: Jan 2011
Posts: 487
Likes: 2
From: Chicago
No, not really. I know that a group of trained engineers designed the system I intend to install. They obviously thought an improvement was in order over the original 1piston and drum brakes.
It's not just "painting old parts" The only parts that are from the donor truck are the spindles, shields and caliper brackets. Everything else is new.
I am fully aware of the differences in a disc/drum vs disc/disc system. If you note in a previous post, I have a master cylinder from a newer truck with 4 wheel disc.
Essentially a brake system is not complex. However it needs parts that are engineered to work together, which is what I am doing.
It's not just "painting old parts" The only parts that are from the donor truck are the spindles, shields and caliper brackets. Everything else is new.
I am fully aware of the differences in a disc/drum vs disc/disc system. If you note in a previous post, I have a master cylinder from a newer truck with 4 wheel disc.
Essentially a brake system is not complex. However it needs parts that are engineered to work together, which is what I am doing.
Thread Starter
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Senior User
Joined: Jan 2011
Posts: 487
Likes: 2
From: Chicago
A fresh set of SuperDuty pads and then the calipers can go on.
Caliper mocked up on passenger side. The rotor and caliper will be removed for spindle installation.
Donor calipers were too nasty to use, so they are now cores for MotorCraft calipers.
Thread Starter
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Senior User
Joined: Jan 2011
Posts: 487
Likes: 2
From: Chicago
So the truck has been on 4 wheel disc brakes for about 2,000 miles and I can say the stopping power is much better. I will be updating this thread on Saturday or Sunday. I will take some pictures of the completed installation.
Tuned
Joined: Feb 2010
Posts: 299
Likes: 6
From: South NJ
Wow - super detailed thread with good info.Nice work! 
Glad that the end result is working well.
I'm late to looking at this... am I summarizing correctly that you installed a complete/newer system with rotors, calipers, master cylinder, proportioning valve and ABS components on the older van?
Glad that the end result is working well.I'm late to looking at this... am I summarizing correctly that you installed a complete/newer system with rotors, calipers, master cylinder, proportioning valve and ABS components on the older van?
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Thread Starter
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Senior User
Joined: Jan 2011
Posts: 487
Likes: 2
From: Chicago
I was able to reuse the original master cylinder, HCU, lines and front hoses. The front brakes and rear brakes are now 2004-06 E150. It does require the use of 16” wheels to clear the bigger brakes.
Tuned
Joined: Feb 2010
Posts: 299
Likes: 6
From: South NJ
I thought that post #30 showed the master cylinder from the '04 donor? Thanks.
Mark
Mountain Pass
Joined: May 2018
Posts: 103
Likes: 3
From: Kansas City/Overland Park
Wow …. much more work than I would ever tackle on my old van. Congrats on a successful modification and the meticulous manner in which you operate, it is very impressive. I just have an '03 E150 conversion van, but one thing I've really noticed when driving it (only had it 6 months), is how good the factory brakes are …. so I would have never thought to 'upgrade' to a different setup. Really glad all your hard work and time involved paid off in a good way. Too many times you hear of all this time, effort, money put into an idea and it turns out to be a waste, so it was great to see yours was successful !!!
