Lastly, I replaced the brake line on the back left that I cut when I was doing the drum brakes. Ford used a large, 7/16 brake fitting on a small 3/16 brake line for the '90 Ranger, and it took me about a day of trying different things to make the repair with parts available.
If you remember from the original diagnosis, the caliper-pins were rusted in, fusing the assembly together. I also think the caliper and pads had rusted partially to the splash shield where the v-grooves meet. To pull them apart, it took some beating with a hammer and a little bit of penetrating oil.
When I pulled the caliper out of the way, I noticed that the brake hose was pretty rotted as well. The ends where it meets the fittings is very worn and brittle, but there is also a chunk of the rubber missing from the middle. You can see in this picture how the hose kinks right at that chunk.
The brake line connects to the hose through the hole in the center of the clip. To remove it, you have to first disconnect the brake line from the hose. Then the tab can be pulled over the fitting while the clip is hammered out.
Packing the bearings is something that I've heard both positive and negative comments on. Personally, I thought it was kind of fun. Of all the things I've done on this truck, packing the bearings is about the simplest, most mindless task I've had to conquer. My only complaint is that every hair, scab, and bug bite on your body itches the second you cover your hands in the grease.
Once the inner bearing was packed, it just dropped into the race and the seal went on pretty easy with some light taps around it with a hammer. Not having to worry about hammering in and out new races really makes the rotors worth the $35. It may not be the right decision if you have quality rotors on a heavy loading vehicle, but I really appreciated that part being taking care of, especially since I had never done it before.
Plan A was to put a flare on what line was left on the truck and use a union to connect in a small patch. I had a lot of trouble, however, getting the flaring tool to hold the brake line tight enough that it wouldn't slip. I finally broke off one of the ears on the wing nuts trying to cinch it down.
For Plan B, I found a 3/8-to-7/16 adapter at O'Riely. That adapter almost worked, but the head on the fitting bottomed out before the flare, and I'm pretty sure it wouldn't hold. All it needed was maybe a 3 or 4 more threads and it would have been a perfect solution.