Range Industries IWC-1324B Big Brake Kit For Explorer 8.8 Axle Instruction Manual
- June 13, 2024
- Range Industries
Table of Contents
Range Industries IWC-1324B Big Brake Kit For Explorer 8.8 Axle
Product Information
Specifications
- Product Name: EPB Big Brake Kit for Explorer 8.8 Axle
- Manufacturer: Range Industries
- Compatibility: Explorer 8.8 Axle
- Includes: Caliper bracket, components for brake kit
Product Usage Instructions
Unpacking and Inspection
Begin by unpacking all components and ensure that no parts are missing. If any parts are missing, please contact sales@range-industries.com for assistance.
- Remove existing components for re-use.
- Install the new caliper bracket and re-assemble the axle.
- Apply blue Loctite to ensure secure fastening.
- Position the bleeder fitting upwards.
- Note: Ensure proper orientation of the parking brake mechanism. One direction sets the parking brake, while the other releases it.
FAQ
- Q: What should I do if any parts are missing from the package?
- A: If any parts are missing, please contact sales@range-industries.com for prompt assistance in resolving the issue.
- Q: How do I ensure the parking brake mechanism is correctly oriented?
- A: One direction on the mechanism sets the parking brake, while the other direction releases it. Make sure to verify the correct orientation during installation.
EPB big brake kit for Explorer 8.8 axle
Begin by unpacking all components and making sure no parts are missing. If any
parts are missing, please contact sales@range-industries.com and we will remedy the situation ASAP. See a list of
all parts below:
PARTS
- 2x Caliper mounting brackets
- 4x M14 x 35mm bolts
- Bolts caliper to bracket
- 2x Caliper connectors, terminals, and seals
- 1x Toggle switch
- 1x 15amp breaker
- Spade and ring terminals
Installation Instructions
Install Notes
- This fits 95-03 Explorer 8.8 solid axles
- You will need calipers and rotors for the 2020-23 Ford Explorer, Ford Interceptor, or Lincoln Aviator. There are 2 variants and either will work with this kit:
- Base Explorer brakes are solid rotors and will fit a 17” or larger wheel.
- Interceptor/ explorer performance/ Lincoln Aviator use a vented rotor and fits 18” or larger wheels.
- You will need to crimp the caliper connector terminals. We recommend the iCrimp IWC-1424B, available on Amazon for approx. $20. We also recommend a ratcheting style crimper for the ring terminals and spade terminals (such as iCrimp IWS-30J and many others)
- You will also need to provide the 16g wire and wire loom required for your installation.
- After driving for 25 miles, re-check the hardware to ensure everything is tight.
Strip the old brakes off the axle
- Remove the wheels and old rotors from the axle.
- Open the differential cover and drain the fluid.
- Remove the retaining bolt for the cross pin of the differential.
- Remove the cross pin.
- Push axle shafts further into the differential to expose the C-clip.
- Remove the c-clip (can be pushed off with a pick or magnet)
- Remove the axle shafts.
- Remove the brake backing plate. Save the bolts for re-use.
Install the new caliper bracket and re-assemble the axle.
- Bolt new brackets to flanges on the axle.
- It can be clocked up or down using the additional holes and can be mounted forward-facing or back-facing.
- Consider replacing axle seals and outer bearings.
- Insert axle shafts, and replace c-clips.
- Pull out on shafts, then install the differential cross pin and retaining bolt.
- Replace the differential cover using an RTV or a gasket.
Install new calipers
- Put rotors in place.
- Bolt-on calipers using supplied bolts. Use blue Loctite. Make sure your bleeder fitting is up.
Plumb the service brakes
- Drill out the end of your old brake hoses to fit the banjo bolt for the new calipers. Use a 10mm drill bit (or 13/32”). Remove chips!
- Use the banjo bolt and crush washers that came with your calipers.
Wire the parking brake
- Wire your system as shown in the diagram (see end of instructions).
- To assemble the caliper connectors, proceed as follows
- Install wire seal
- Strip wire
- Crimp terminal
- Crimp seal
- Insert into the connector body
- Click the gray cap into place
- Be sure that both calipers are connected with the same polarity (otherwise one will clamp while the other unclamps
Operation of the parking brake
-
The toggle switch is a momentary operation. One direction sets the parking brake, while the other releases it.
-
To set the brake, hold the switch until the motor makes a straining noise.
-
To release the brake, hold the switch for approximately 3 seconds.
-
If you hold the brake too long when applying the brakes, the circuit breaker will trip. It will automatically reset after approximately 30 seconds and operation can be resumed.
-
The calipers are designed to stall, and the circuit breaker protects the switch and motors from overcurrent, so you cannot harm the system.
-
Test the holding power of your brakes in a controlled and safe manner on a hill to get a feel for the operation of the brakes.
-
These electric brakes require no adjustments and have exceptional holding power. When doing a brake job, they can be fully retracted using the toggle switch.
