2002 Mercury Grand Marquis Brake Service (ONLINE REPAIR MANUALS)

Remove wheels and inspect brake disc, caliper and linings. Inspect wheel bearings and repack if required.

If the caliper is cracked or fluid leakage through the casting is evident, it must be replaced as a unit.

If caliper is removed when installing new components, clean all components in alcohol, then wipe dry using lint-free cloths. Blow out drilled passages and bores with compressed air. Inspect dust boots for punctures or tears, replace as required.

Inspect piston bores in both housings for scoring or pitting. Bores showing light scratches or corrosion can be cleaned with crocus clo...

Parking Brake

Cougar, Crown Victoria, Grand Marquis, Marauder & Town Car

• Apply parking brake control fully with 100 lbs., foot pedal effort, then release brake control.
• Place transmission in Neutral, then raise and support vehicle.
• With parking brake control in Off position, grasp pensioner around housing. Using an hook tool place end into rounded end of clip between clip and housing. Unlock clip by pulling downward with tool and support pensioner.
• The pensioner spring will take up cable slack and reload cables, while holding pensioner, lock clip by pushing up on bottom of clip. If clip ...

Pressure bleeding is recommended for all hydraulic disc brake systems.

Do not use brake fluid drained from the hydraulic system when bleeding the brakes. Ensure disc brake pistons are returned to their normal positions and the shoe and lining assemblies are properly seated. Before driving the vehicle, inspect the brake operation.

Do not shake the pressure bleeder tank while air is being added or after it has been pressurized. This will prevent air from the tank getting into the lines. Set the tank in the required location, then bring the air hose to the tank. Do not move the ta...

Disc brake service is 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 required to prevent brake roughness. In addition, the surface finish must be non-directional and maintained at a micro-inch finish. This is required 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 ...

Pre-Test Checks

• Verify parking brake is completely released. If parking brake is applied, "Brake" lamp will be illuminated.
• Check brake fluid. As fluid level drops, red "Brake" lamp will illuminate. If fluid level continues to fall, amber "Check Anti-Lock Brake" lamp will illuminate and anti-lock function will be inhibited.
• Verify all of the following connectors are properly connected and in good operating condition:
• Connector of...

If caliper does not require servicing, do not disconnect brake hose or remove caliper from vehicle. Position caliper aside with wire or tie straps to avoid damaging caliper or hose.

If excessive force must be used to remove the rotor, then it should be inspected for lateral runout before installation.

Removal

• On models equipped with air suspension, turn service switch Off.
• On all models, raise and support vehicle, then remove wheel and tire assembly. Use care to avoid damage or interference with caliper bleeder screw fitting and brake rotor shield.
• Remove caliper anchor bracket bol...