1994 Mercury Sable Brake Service (ONLINE REPAIR MANUALS)

On vehicles equipped with anti-lock brakes refer to appropriate "Anti-Lock Brakes".

Complaints about power brake operation should be handled as if two separate systems exist. Check for faults in the hydraulic system first. If it is satisfactory, start inspecting the power brake circuit. For a quick check of proper power unit operation, press the brake pedal firmly and then start the engine. The pedal should fall away slightly and less pressure should be needed to maintain the pedal in any position.

Another check begins with installation of a suitable pressure gauge in the brake hydr...

Disc brake service is extremely critical due to the close tolerances required in machining the brake disc to ensure proper brake operation.

Maintaining close control of the shape of the rubbing surfaces is necessary to prevent brake roughness. In addition, the surface finish must be non-directional and maintained at a micro-inch finish. This is necessary to avoid pulls and erratic performance and promote long lining life and equal lining wear of both the left and right brakes.

Do not attempt to refinish the rubbing surfaces unless precision equipment, ca...

On vehicles equipped with anti-lock brakes refer to appropriate "Anti-Lock Brakes".

PUSHROD

Proper adjustment of the master cylinder pushrod is necessary to ensure proper operation of the power brake system. A pushrod that is too long will prevent the master cylinder piston from completely releasing hydraulic pressure, eventually, causing the brakes to drag. A pushrod that is too short will cause excessive brake pedal travel and cause groaning noises to come from the booster when the brakes are applied. A properly adjusted pushrod that remains assembled to the booster with which is was ...

MASTER CYLINDER OVERHAUL

Disassemble

• Clean outside of master cylinder thoroughly. Drain brake fluid from master cylinder.
• Remove stop bolt and pressure control valves, if equipped.
• Using a screwdriver, carefully pry up on reservoir and remove it from master cylinder body.
• Remove fluid control valve, if equipped.
• Depress primary piston and remove snap ring from retaining groove at open end of bore.
• Remove primary and secondary piston assemblies from master cylinder. If secondary piston does not come out, apply air pressure to secondary outlet port to remove.

Inspection

When disassembled...

CALIPER, REPLACE

MARK VII

Removal

• Raise and support vehicle, then remove tire and wheel assemblies.
• Disconnect fitting on rear brake tube from hose end fitting at frame mounted bracket. Plug end of brake tube to prevent fluid loss and entry of dirt.
• Remove horse shoe retaining clip from hose fitting and disengage hose from bracket.
• Disconnect parking cable from lever, Fig. , using care to avoid kinking or cutting cable or return spring, then remove screw from caliper key, Fig. , then remove caliper locating pins.
• Slide caliper key and support spring from anchor plate, Fig. , noting the...

CONTINENTAL, COUGAR, MARK VII, MARK VIII, MUSTANG & THUNDERBIRD

Sliding caliper rear disc brakes are used on Continental, Mark VII, Mark VIII, Mustang and Thunderbird, Figs. through . The caliper is basically the same as the larger front wheel caliper; however, a parking brake mechanism and a larger inner brake shoe anti-rattle spring have been added.

The parking brake lever, located at the rear of the caliper, is actuated by a cable system similar to rear drum brake applications. When the parking brake is applied, the cable rotates the lever and operating shaft, driving the caliper ...