2002 Mercury Sable Brake Service (ONLINE REPAIR MANUALS)

Replacement

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.

Continental, Cougar, Crown Victoria, Grand Marquis, LS, Marauder, Mustang (Except Cobra), Sable, Taurus, Thunderbird & Town Car

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

• On models equipped with air suspension, turn air suspension service switch to Off position.
• On...

Continental, Cougar, Mustang, Sable & Taurus

Removal

• Remove rear disc brake caliper assembly as outlined under "Caliper Service." Do not disconnect flexible hose unless caliper requires service. Support caliper with wire or tie strap so flexible hose is not stretched or twisted.
• Remove rear disc support bracket to wheel knuckle bolts, then the rear disc support bracket and brake shoes and linings.
• Remove two nuts, then the rotor from rear hub.

Installation

• If installing new rotor, remove protective coating from rotor with suitable carburetor cleaner.
• Lubricate rear hub pilot diameter w...

Complaints about power brake operation should be handled as if two separate systems exist. Inspect for faults in the hydraulic system first. If it is satisfactory, start inspecting the power brake circuit. For a quick inspection of proper power unit operation, press the brake pedal firmly and then start the engine. The pedal should fall away slightly and less pressure should be needed to maintain the pedal in any position.

Another inspection begins with installation of a suitable pressure gauge in the brake hydraulic system. Take a reading with the engine Off and the power unit n...

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 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 equipme...

Brake Roughness

Thickness Variation

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. Measure the disc at 12 points with a micrometer at a radius approximately one inch from edge of disc. If thickness measurements vary by more than .0005 inch, replace the disc.

Lateral Runout

Excessive lateral runout of braking disc may cause a "knocking back" of the pistons, possibly creating increased pedal travel and vibration when brakes are applied.

Wheel Bearing Looseness

Adjust the w...

Master Cylinder Overhaul

Disassemble

• Clean outside of master cylinder thoroughly. Drain brake fluid from master cylinder.
• Remove stop bolt and pressure control valves, if equipped.
• Pry up on reservoir and remove it from master cylinder body.
• Remove fluid control valve, if equipped.
• Depress primary piston and remove snap ring from retaining groove at open end of bore.
• Remove primary and secondary piston assemblies from master cylinder. If secondary piston does not come out, apply air pressure to secondary outlet port to remove.

Inspection

When disassembled, wash all parts in clean brake...