1996 Ford Contour Brake Service (ONLINE REPAIR MANUALS)

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 matched during production should not require service adjustment. However, if the b...

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...

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 ...

Caliper, Replace

Capri

• Raise and support vehicle, then remove wheel and tire assembly.
• Remove brake pads as described under "Brake Pad Service."
• Remove clip brake flex hose to strut assembly clip.
• Remove brake flex hose to caliper assembly banjo bolt.
• Remove two copper washers sealing flex hose banjo fitting, then discard washers.
• Remove lower caliper retaining bolt.
• Using cold chisel, remove upper caliper guide pin dust cap. This will allow access to Allen head on guide pin.
• Using Allen wrench, loosen and remove upper caliper guide pin.
• Lift caliper off rotor.
• Remove guide pin and bushing d...

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...

Pressure bleeding is recommended for all hydraulic disc brake systems.

The disc brake hydraulic system can be bled manually or with pressure bleeding equipment. The brake pedal will require more pumping and frequent inspecting of fluid level in master cylinder during bleeding operation.

Do not use brake fluid drained from the hydraulic system when bleeding the brakes. Be sure the disc brake pistons are returned to their normal positions and the shoe and lining assemblies are properly seated. Before driving the vehicle, inspect brake operation to be sure a firm pedal has been ob...