Upgraded front brakes-pre 2008 E450

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Upgraded front brakes-pre 2008 E450

November 18, 2024, 12:26:18 pm

In 2008, Ford upsized the E450's front brakes significantly.
I'm a few years late, only recently discovering that the front brakes of the pre-2008 E450s can use the same brake rotors, calipers, and pads as the 2008 and later E450s. To complete the package, new caliper brackets, caliper bolts, and brake hoses are required.
The rotors are slightly larger in diameter and almost a half-inch wider. They are also 13 lbs heavier, more mass to absorb braking energy. The brake pads and caliper pistons are larger.
https://www.ford-trucks.com/forums/1277783-08-brake-upgrade-with-photos.html#post13736585

If a brake job is on the horizon for your pre-2008 E450, consider this upgrade, especially if you tow.
Towing heavy Jeeps have caused our LD's front brake rotors to warp twice. The next time the brakes need work, the 2008 and later front brakes will be installed.

Larry

Re: Upgraded front brakes-pre 2008 E450

Reply #1 – November 19, 2024, 09:21:19 pm

Larry, this is great news. When I bought mine, the front rotors are warped and a brake job is on the horizon, especially before Morro Bay. We do plan on towing in the future so this is a must.

In reading your linked thread, it says to convert the E-250's? This thread seems to get confused as more people added info so now I am a little confused. Was thinking I would see the pre-2008 E450 conversion to 2008 E450 with pix, part #s etc. but think this was just an example and one just needs to buy all 2008+ E450 parts.

Ramon

Re: Upgraded front brakes-pre 2008 E450

Reply #2 – November 20, 2024, 06:03:00 pm

I spent a bit of time on Rock Auto cross-referencing the brake part specifications for the 2003 and 2008 E250, E350, and E450.
It looks like everything should fit. The 2008's knuckles, caliper, caliper brackets, rotors, and pads have the same.part numbers for the E250, E350, and E450.. The same front brakes are used from 2008 to the latest E-series models.
The E450's increased braking power is the result of the greater hydraulic pressure brake line pressure produced by the hydro-boost. The E250 and E350 have vacuum brake boosters, compared to the E450's hydro-boost.

An amazing amount of E450 parts have been interchangeable through the years, except the electronics.
Assume I will try this conversion before next summer's longer trip.

Larry

Re: Upgraded front brakes-pre 2008 E450

Reply #3 – November 20, 2024, 07:48:02 pm

Thanks Larry, If I am the first one to pull this off, I will post but probably after all the holidays
Ramon

Re: Upgraded front brakes-pre 2008 E450

Reply #4 – Today at 09:12:45 am

Quote from: Larry W - November 18, 2024, 12:26:18 pm

In 2008, Ford upsized the E450's front brakes significantly.
I'm a few years late, only recently discovering that the front brakes of the pre-2008 E450s can use the same brake rotors, calipers, and pads as the 2008 and later E450s.

Do the 2008's have better specifications due to the better front brakes, like a higher maximum towing weight, than the earlier E450's?

Re: Upgraded front brakes-pre 2008 E450

Reply #5 – Today at 11:26:38 am

Quote from: mrfixit454 - November 20, 2024, 07:48:02 pm

Thanks Larry, If I am the first one to pull this off, I will post but probably after all the holidays
Ramon

It should not be hard changing to the larger brakes, nothing is exceptionally mechanically challenging, the biggest issue for me is the weight of the rotors.
If you have decent size air compressor, save up for a Harbor Freight pneumatic/hydraulic jack. it comes in handy along with a set of 12-ton jack stands.
https://www.harborfreight.com/12-ton-airhydraulic-bottle-jack-59425.html

The new front rotors require bearings and seals. They come with the races already pressed in. The wheel roller bearings need a slight preload, I use a Parks bicycle torque wrench to set it to 18 in/lbs.

The 2008 brakes require different brake hoses, but they have the same thread size as your LD. While you are doing this, it's a good time to replace all the rubber brake lines in your nearly quarter-century-old LD.
Finding the correct rear hoses was challenging when I rebuilt our 2003 LD brakes two summers ago. It required a bit of mixing and matching, and the OE lines were no longer available.
As the rear brakes seem adequate, I have found no listing of upgrades.

Larry

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