1996 Mercury Sable Brake Service (ONLINE REPAIR MANUALS)

Removal

• Raise and support rear of vehicle, then remove tire and wheel assembly.
• Remove brake drum and hub as follows:
• Remove drum retainer push nuts, then slide drum off hub, Fig. .
• If drum is stuck to hub, use a suitable hammer to lightly tap on face of drum in flange mounting area to release.
• If brake lining is dragging on brake drum, back off brake adjustment by holding adjustment lever off star wheel, then loosen star wheel, Fig. .
• Remove hub nut cover and discard.
• Remove hub nut and discard, then slide hub and one-piece bearing assembly off spindle.
• Install suitable wheel cylinder pi...

Master Cylinder

Except Capri, Escort, Sable, Taurus & Tracer

• On models equipped with ABS, depress brake pedal several times to exhaust all vacuum in the system.
• On all models, disconnect brake lines from master cylinder, then all necessary electrical connectors.
• On models equipped with ABS, disconnect hydraulic control unit supply hose at master cylinder. Secure hose in a position to prevent brake fluid loss.
• On all models, remove nuts retaining master cylinder to brake booster.
• Remove master cylinder.
• Reverse procedure to install. After installation is complete, fill master cyli...

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...

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 when installing new parts, clean all parts in alcohol, then wipe dry using lint-free cloths. Using an air hose, blow out drilled passages and bores. Inspect dust boots for punctures or tears. If punctures or tears are evident, install new boots during assembly.

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On models with anti-lock brakes, the brake hydraulic 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

Removal

• Remove brake fluid until reservoir is half full.
• On Continental, Sable and Taurus, if equipped, turn air suspension service switch Off.
• On all models, raise and support front of vehicle, then remove wheel and tire assembly.
• Remove caliper locating pins.
• Lift caliper assembl...

Capri

Removal

• Raise and support vehicle, then remove wheel and tire assembly.
• Using cape chisel, unstake and remove halfshaft nut and washer. Discard nut if it cannot be used again.
• Remove disc brake pads as described under "Brake Pad Service," then the caliper as described under "Caliper Service." Support caliper by suitable wire strung from coil spring. Do not disconnect brake line from caliper.
• Remove grease cap, then carefully raise staked portion of locknut using small cape chisel.
• Remove and discard locknut. Locknuts are threaded left and right. Lefthand threaded locknut is located o...