Front knuckle/brake upgrade

[Hyrum91]

My truck is a 1991 ranger super cab with 4x4, auto trans, and the tick tick ticking 4.0
And idk if its relevant but it has a lift that I've been told is 4 inches

Now that we got that out of the way,
My front brakes have an issue that from my research is very common. The knuckles have warn and chipped off a bit at the end of the brake pad slide. So when my brake pads wear down enough the brake pads decide they want to fall out. from what I've read about in this website and explorer websites my options are to 1: pull knuckles from an explorer or ranger like mine or 2: pull knuckles from an explorer/ranger from 95+ that doesn't have knuckles that wear.
I don't like having knuckles as a regular replaceable item so I've decided to go with the second option and I'd just like to confirm before I take apart my truck and realize I've done something wrong.
To do this swap I'm going to need:
95+ knuckles, calipers, caliper brackets, discs, and pads.
The questions I then have are: do I need new lines or are my current lines going to bolt right to the 95+ calipers. And the other question is do I need different ball joints. The reason I ask this is because I just did my new ball joints at the end of this last year. I'm okay to buy new ones I'd just like to save money if I can reuse them.

Sorry for the huge paragraphs, I didn't want to leave out any info that you wise guys might need. Thanks in advance

 

[JoshT]

I knew that the 2WD changed from the clips to bolt-on in 95, did not realize that there was a change for the 4wds as well. Never messed with a pre-98 4x4. Dad had a 90 BII, but I never worked on it. I'll have to keep that in mind for future build dreaming, like you I prefer the bolt-on setup for calipers.

Don't know about brake hoses. Listings do not show them as being cross compatable, but that does not mean they won't physically attach to the later calipers. The banjo bolt bor both is the same size, and the caliper itself is located in about the same location. The pad/boss that the hose end seals to is different location and shape, so it may cause interference. Seeing how you'll have to bleed the brakes either way, if the hoses have any appreciable age on them I'd replace them with the calipers.

EDIT: Missed the 4" lift part. If it has lengthened brake hoses to match the lift, you may be safe on using them with the new calipers. Many times those extended hoses are built using a little more universal components than what the OE replacement hoses would use. Be worth looking a little closer and maybe posting a picture to get a better answer. Still might be worth replacing them while the system is open if they have any appreciable age.

According to RockAuto parts listings, the same ball joints were used from 89-97 on the 4x4 Rangers. You should be good to go there assuming that they aren't damaged during the swap.

Don't worry about the paragraphs. They are understandable and shorter than what I often find myself writing.

 

[SenorNoob]

I did essentially this. Don't forget dust shields. They are VERY different. In my case with a 4" lift the factory 95-97 hoses work fine.

If you're junkyard shopping, the calipers and brackets can come from a 95+ Explorer. Mine are. I got those dust shields too but the bolt hole didn't line up. I drilled new ones.

 

[85_Ranger4x4]

Brake hoses are different... or at least they were from my D28.

The steering stops are different as well. I don't remember if the earlier ones have the stops in the beam and the later has them in the knuckle or what the deal was but there is a difference there. Ideally it is best to grab the beams as well but you can make it work.

 

[Shran]

Personal preference here. I greatly prefer the old style calipers and slide pins vs 95+. I have never seen the pads fall out, but I have definitely seen the pins fall out, as a result of reusing them way too many times. That is the ONE weak link on those. 95+ and just about every other vehicle on the road today has slide pin bolts that fall victim to rust. I have only had a stuck caliper on a 94 and older a couple times and never a stuck slide pin issue... slide pin bolts on the other hand, a LOT. IMO it's really unfortunate that every vehicle has that style these days. You can destroy a set of pads, rotor, and a caliper in a very short period of time. They have almost made it to where taking everything apart and cleaning/lubing the slide pin bolts needs to be a routine maintenance item.

Simple & reliable has disappeared in favor of complicated and stupid.

 

[85_Ranger4x4]

Personal preference here. I greatly prefer the old style calipers and slide pins vs 95+. I have never seen the pads fall out, but I have definitely seen the pins fall out, as a result of reusing them way too many times. That is the ONE weak link on those.

My parent's 94 Explorer had knuckle wear so the pads would like to cock sideways and jam and eat the rotor.

But my '85 was perfect.

I've never had an issue with slide pins, hands down I prefer them.

 

[lil_Blue_Ford]

I have to say I like the simplicity of the old slide pins. I had one acting like it was sticking a little on my Choptop. 5 minute fix, jacked it up, pulled the tire, knocked the slide pins out, cleaned the mating surfaces, couple dabs of brake grease and back together. I’d spend twice that time servicing the bolt-on calipers and slide pins especially because cleaning out the bores of old grease and corrosion pretty much requires sending a drill bit down there.

 

[mr_manny]

I thought the upgrade was only ranger knuckles.
Thanks for the education.

 

[85_Ranger4x4]

I thought the upgrade was only ranger knuckles.
Thanks for the education.

95-97 Rangers were the only ones to get bolt on calipers.

It sounds like 95-01 Explorers may share calipers though.

 

[Shran]

My parent's 94 Explorer had knuckle wear so the pads would like to cock sideways and jam and eat the rotor.

Crazy, I have never seen that happen on a TTB truck. Learn something new every day.

I did find out that Super Duty rear pads will fall out of the caliper and jam up the rotor & caliper if you let them burn down past the friction material... things become very unhappy.

 

[85_Ranger4x4]

Crazy, I have never seen that happen on a TTB truck. Learn something new every day.

I did find out that Super Duty rear pads will fall out of the caliper and jam up the rotor & caliper if you let them burn down past the friction material... things become very unhappy.

Dad got so sick of it he took it to the Ford dealer which had never happened before. They couldn't figure it out either. Like once a year before vacation every year the brakes had been making noise so we would put new pads and rotors on it. Pads and rotors had been in a mutually destructive war every time.

It wasn't until I got on here and AllenD explained it that it made perfect sense what was happening lol.

As TTB trucks were drying up when I happened upon my '95 D35 for a song... not having the knuckle be a wear item was very appealing.