1995 Mercury Cougar Brake Service (ONLINE REPAIR MANUALS)

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 lefthand and righthand brakes.

Do not attempt to refinish the rubbing surfaces unless precision equip...

Parking Brake

Aspire

• Ensure parking brake control lever is in fully released position.
• Remove access cover from console.
• Remove cable adjustment nut's locking clip.
• Raise and support vehicle, then ensure rear tires turn freely.
• Tighten cable adjustment nut until brakes drag slightly when tires rotate.
• Loosen adjustment nut in small increments until drag just disappears.
• Rear brakes should lock when brake control lever is pulled upward 11-16 notches.
• Ensure parking brake operates properly.
• Install locking clip and access cover.

Continental, Cougar, Mustang & Thunderbird

• Fully release parking bra...

Caliper, Replace

On models with anti-lock brakes, the brake booster system must be depressurized before disconnecting any hydraulic lines or fittings. Depressurize the system by pumping the brake pedal a minimum of 25 times with the ignition in the Off position.

Except Aspire, Capri, Escort, Mustang Cobra, Probe & Tracer

Before removing calipers, mark lefthand and righthand calipers so they can be installed in the same position.

• On Continental, Sable and Taurus, turn air suspension service switch Off, if equipped.
• On all models, raise and support front of vehicle, then remove wheel a...

Brake Roughness

The most common cause of brake chatter on disc brakes is a variation in thickness of the disc. If roughness or vibration is encountered during highway operation or if pedal pumping is experienced at low speeds, the disc may have excessive thickness variation. To inspect for this condition, measure the disc at 12 points with a micrometer at a radius approximately one inch from the edge of the disc. If t...

Whenever new brake components are installed in the hydraulic system, it is recommended that the entire hydraulic system be thoroughly flushed with clean brake fluid.

It may sometime become necessary to flush out the system due to the presence of mineral oil, kerosene, gasoline, etc., which will cause swelling of rubber piston cups and valves and render them inoperative.

Flushing is performed at ...

Vacuum Assist Diaphragm Type

The vacuum assist diaphragm assembly multiplies the force exerted on the master cylinder piston in order to increase the hydraulic pressure delivered to the wheel cylinders while decreasing the effort necessary to obtain acceptable stopping performance.

Vacuum assist units get their energy by opposing engine vacuum to atmospheric pressure. A piston, cylinder and flexible diaphragm utilize this energy to provide brake assistance. The diaphragm is balanced with engine vacuum until the brake pedal is depressed, allowing atmospheric pressure to unbalance the u...