1990 Mercury Cougar Brake Service (ONLINE REPAIR MANUALS)

• Raise and support rear of vehicle, then remove tire and wheel assembly.
• Remove brake drum.
• Install suitable wheel cylinder clamp over ends of wheel cylinder to retain pistons in bore.
• Disconnect parking brake cable from parking brake lever.
• Remove two brake shoe hold down retainers, sprin...

REMOVAL

Except Capri, Festiva, Tracer, Scorpio, XR4Ti, Probe & 1991 Escort

Before removing calipers, mark left and right hand calipers so they can be installed in the same position.

• Raise and support front of vehicle, then remove wheel and tire assembly.
• Loosen brake tube fitting which connects brake tube to fitting on frame and plug brake tube. Remove retaining clip from brake hose and bracket, then disconnect brake hose from caliper.
• Remove caliper locating pins.
• Lift caliper from rotor and spindle anchor plate assembly.On models equipped with phenolic caliper piston, do not pry directly ag...

Remove wheels and inspect brake disc, caliper and linings. The wheel bearings should be inspected at this time and repacked if necessary. Do not get any grease on the linings.

If the caliper is cracked or fluid leakage through the casting is evident, it must be replaced as a unit.

Should it become necessary to remove the caliper for installation of new parts, clean all parts in alcohol, wipe dry using lint free cloths. Using an air hose, blow out drilled passages and bores. Check dust boots for punctures or tears. If punctures or tears are evident, new boots should be installed upon re...

The hydraulic pump maintains system pressure between approximately 2030-2610 psi, within the accumulator and is connected by a high pressure hose to the booster chamber portion of the hydraulic actuation assembly and a control valve. When the brakes are applied, a scissor lever mechanism activates the control valve and a pressure, proportional to brake pedal travel, enters the booster chamber portion of the hydraulic actuation assembly. This pressure is transmitted through the normally open solenoid valve through the proportioning valve to the rear brakes. The same pressure mov...

REMOVAL

Except Capri, Festiva, Tracer, Scorpio, XR4Ti, Probe & 1991 Escort

• Remove brake fluid until reservoir is half full.
• Raise and support front of vehicle, then remove wheel and tire assembly.
• Remove caliper locating pins.
• Lift caliper assembly from adapter plate, then remove outer shoe from caliper assembly.On some models, slip shoe down caliper leg until clip is disengaged.
• Remove inner shoe and lining assembly.On some models, pull shoe straight out of piston. This should require a force as high as 20-30 lbs.
• Suspend caliper from inner fender housing with wire to avoid damaging brake ...

BRAKE DRUMS

Any time the brake drums are removed for brake service, the braking surface diameter should be checked with a suitable brake drum micrometer at several points to determine if they are within the safe oversize limit stamped on the brake drum outer surface. If the braking surface diameter exceeds specifications, the drum must be replaced. If the braking surface diameter is within specifications, drums should be cleaned and inspected for cracks, scores, deep grooves, taper, out of round and heat spotting. If drums are cracked or heat spotted, they must be replaced. Mi...