1994 front brakes

[eaglescout94]

I found out the passenger side steering knuckle has worn through the upper brake pad slot. With some looking I was able to find that the 95-97 brakes will swap over using their knuckle, rotor and calipers. Is this the only upgrade option or does anyone have a reasonable fix for the 94 knuckle to be able to hold a brake pad in place again? Im super close to getting my manual swapped truck on the road and this kinda throws a wrench in the plans.

 

[JoshT]

Is this a 2wd or a 4wd?

I'm not too familiar with the 4x4 stuff, but I'm fairly certain that is the limit of upgradability on them. I'm not familiar enough with those early knuckles to understand what happened or recommend a possible repair for it other than rteplace with a like part.

For the 2wds there are a few more options. Of course the same 95-97 knuckles and brake swap path, or sport track and "cobra" options based on the same later model knuckles. Repair options are about the same, replace the knuckle.

Maybe you could find a machine shop that would weld it up and remachine the slot, but they probably won't like the idea of welding on the cast piece.

Both 2wd and 4wd upgrade are mentioned in one of the articles in out tech library.

 

[eaglescout94]

It’s a 4wd. New parts don’t seem to exist unfortunately. I’ll probably end up going to a lot of auto yards and getting my hands on any piece I can to fix mine and had on standby.
I’d thought about a machine shop or welding shop, might still give em a call to see what they say

 

[lil_Blue_Ford]

So, the knuckle being cast, it can be fixed, but most places probably won’t because to do it right requires pre-heating and slow cooling.

Junkyard is likely the only place to find a knuckle these days. A 4.0l truck would have a D-35 TTB front for your gen. Those axles existed in 1990-97 Rangers*, 1990 Bronco II, and 1991-94 Explorer.

*all 4.0l Rangers got this axle. You may find it with some other engines. The 2.3l trucks got a D-28 for some years. The 3.0l got a D-28/35 hybrid (beams, knuckles, brakes, hubs and outer shafts were D-35, the inner shafts and pumpkin guts were D-28, they have a smooth pumpkin, no ribs or fins like the other ones.

There is an upgrade converting to D-44 knuckles and outers. Brakes and all of that. But it changes your bolt pattern to 5x5.5” There was some discussion recently somewhere on here about this all.

 

[SenorNoob]

Be aware that at the same time the brakes changed to dual-piston, removable calipers. The steering stops moved from the knuckle to the axle, if that matters to you. It didn't to me.

1994 Spindle/Knuckle Assembly, Front Ford Ranger

A​

U0031

$125​

Archies Auto Recyclers USA-IN(Merrillville) Request_Quote 219-981-0122 Request_Insurance_Quote

110​

That is from Car-Part.com

 

[eaglescout94]

Found out a coworker has a 93 ranger with a 4.0 and manual in it sitting in his pasture. Knuckles and the brake mounts are solid on it so hoping he’s willing to sell the whole truck for a reasonable price