1996 Ford Crown Victoria Brake Service (ONLINE REPAIR MANUALS)

Capri

Removal

• Raise and support vehicle, then remove wheel and tire assembly.
• Using chisel, unstake and remove halfshaft nut and washer. Discard nut and washer.
• Remove brake pads and caliper from steering knuckle as described under "Brake Pad Service."
• Support caliper with wire strung from coil spring. Do not disconnect brake line from caliper.
• Using tie rod end separator tool No. T85M-3395-A, or equivalent, disconnect tie rod end from steering knuckle.
• Remove ball joint pinch bolt, then separate control arm from steering knuckle.
• Remove steering knuckle to strut assembly bolts.
• Using knuck...

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...

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 to 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 equipment, ...

The anti-lock system (ABS), Fig. , controls each brake separately. The brake pedal force required to engage the system may vary with road surface conditions. A dry surface will require a high force, while a slippery surface will require a much less force. During system operation, the driver will sense a slight brake pedal pulsation accompanied by a rise in brake pedal height and a clicking sound. The pedal effort and pedal feel during normal braking are similar to a conventional power brake system.

System Components

Vacuum Booster

The diaphragm type brake booster is self-contained and ...

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...

• On models equipped with anti-lock brakes, hydraulic system must be depressurized prior to disconnecting any hydraulic lines or fittings, by pumping the brake pedal a minimum of 25 times with ignition in Off position.
• On all models, grease or any other foreign material must be kept off caliper, disc surfaces and external hub surfaces during service procedures. Handling brake disc and caliper should be done in a way to avoid deforming disc and nicking or scratching brake linings.
• If inspection reveals rubber piston seals are worn or damaged, they should be replaced immediately.
• During wh...