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Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 2002 Mercury Villager car and truck
repair procedures including Mercury engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
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BRAKE SERVICE PROCEDURES FOR 2002 Mercury Villager AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2002 Mercury Villager cars and light trucks from 1990+.
Disc Brakes -> Description -> 1999-2001 -> 2002-03 -> Aviator -> E-Series -> Escape -> Excursion, F-Super Duty & Motorhome -> Expedition & Navigator -> Explorer & Mountaineer -> Explorer Sport/Sport Trac -> F-Series -> Front -> Ranger -> Rear -> Villager -> Windstar
Vehicle: 2002 Mercury Villager 3.3 V6 GAS
Aviator
Front
The Aviator utilizes a dual piston front brake caliper and a single piston rear brake caliper. The caliper floats on two guide pins that are bolted to the caliper and extend into the caliper anchor, Fig. .
Rear
The rear disc brake system utilizes a single piston brake caliper. The mechanical parking brake system uses a drum in hat system within the rear brake disc, Fig. .
E-Series
Front
The disc brake caliper is a pin slider, single piston design on the E-150 models and a pin slider dual piston design on the E-250, E-350, E-450 & E-550 models, Figs. through .
Rear
E-Series veh...
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BRAKE SERVICE PROCEDURES FOR 2002 Mercury Villager AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2002 Mercury Villager cars and light trucks from 1990+.
Power Brake Units -> Bendix Vacuum Brake Booster -> Power Brake Unit Service
Vehicle: 2002 Mercury Villager 3.3 V6 GAS
The Bendix vacuum brake booster unit is se...
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BRAKE SERVICE PROCEDURES FOR 2002 Mercury Villager AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2002 Mercury Villager cars and light trucks from 1990+.
Hydraulic Brake Systems -> Component Replacement -> Aviator -> E-Series -> Escape -> Excursion & F-Super Duty -> Expedition, Explorer, Explorer Sport & Sport/Trac, F-150, F-250LD, Mountaineer & Navigator -> Less Hydro Max -> Master Cylinder -> Ranger -> Villager -> Windstar -> With Hydro-Max
Vehicle: 2002 Mercury Villager 3.3 V6 GAS
Master Cylinder
Aviator
Remove components in sequence illustrated,. Fig. .
E-Series
- Drain brake master cylinder with suitable suction device.
- Remove coolant reservoir.
- On models equipped with Hydro Boost, remove three power distribution box bracket bolts and position box aside.
- On all models, remove speed control deactivator switch.
- Disconnect fluid level sensor connector.
- Remove and discard master cylinder mounting nuts.
- Disconnect master cylinder brake tubes.
- Remove master cylinder cylinder.
- Reverse procedure to install, noting the following:
- Torque master cylinder mounting nuts to 1...
CLICK HERE TO GET FULL ACCESS TO 2002 Mercury Villager BRAKE SERVICE PROCEDURES
BRAKE SERVICE PROCEDURES FOR 2002 Mercury Villager AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2002 Mercury Villager cars and light trucks from 1990+.
Power Brake Units -> Bendix Vacuum Brake Booster -> Brake Booster Replacement -> Aviator -> E-Series, Expedition, Explorer, Explorer Sport & Sport/Trac, F-150 & F-250LD, Mountaineer, Navigator & Villager -> Escape -> Excursion & F-Super Duty -> Ranger -> Windstar
Vehicle: 2002 Mercury Villager 3.3 V6 GAS
Aviator
Refer to. Fig. , and remove components in sequence illustrated. Use new nuts when installing brake booster.
Excursion & F-Super Duty
- Remove air cleaner housing, if required.
- Remove brake master cylinder attaching nuts.
- Position brake master cylinder aside.
- Disconnect booster vacuum hose.
- Disconnect power distribution box auxiliary relay and set aside.
- Remove fuse panel cover.
- Remove brake pedal position switch self-locking pin.
- Remove brake pedal position switch and brake booster pushrod from brake pedal pin.
- Remove power brake booster nuts.
- Remove power brake booster.
- Reve...
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BRAKE SERVICE PROCEDURES FOR 2002 Mercury Villager AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2002 Mercury Villager cars and light trucks from 1990+.
Hydraulic Brake Systems -> Brake System Bleed -> Anti-Lock Brake System Hydraulic Control Unit -> Anti-Lock Brakes -> Aviator, Explorer & Mountaineer -> Bench -> Caliper -> E-Series & F-Series -> Escape -> Excursion, Explorer Sport/Sport Trac, F-Super Duty, Motorhome, Ranger & Windstar -> Expedition & Navigator -> Four Wheel Anti-Lock Brake System -> Gravity -> Gravity Bleed -> In Vehicle -> Manual -> Manual Bleed -> Master Cylinder -> Pressure -> Pressure Bleed -> Villager
Vehicle: 2002 Mercury Villager 3.3 V6 GAS
Aviator, Explorer & Mountaineer
Master Cylinder
- Connect one end of a clear flexible hose to master cylinder bleeder screw. Submerge other end in a container partially filled with suitable brake fluid.
- Have an assistant pump and then hold firm pressure on brake pedal.
- Open master cylinder bleeder screw until brake fluid flows into container.
- When fluid stops flowing, close bleeder screw.
- Repeat procedure until there are no air bubbles in fluid.
- Have an assistant pump and then hold firm pressure on brake pedal.
- Loosen a master cylinder tube fitting at anti-lock brake hydraulic control ...
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BRAKE SERVICE PROCEDURES FOR 2002 Mercury Villager AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported 2002 Mercury Villager cars and light trucks from 1990+.
Disc Brakes -> Adjustments -> E-250 w/Tension Limiter -> E-450 & E-550 -> E-Super Duty -> Expedition, Explorer, Navigator, Mountaineer & F-250LD -> Parking Brake -> Rear Disc -> Windstar
Vehicle: 2002 Mercury Villager 3.3 V6 GAS
Parking Brake
Expedition, Explorer, Navigator, Mountaineer & F-250LD
Rear Disc
- Remove rear disc brake rotor as outlined in "Rotor, Replace."
- Measure inside diameter of parking brake drum using brake adjustment gauge tool No. D81L-1103-A, or equivalent, Fig. .
- Adjust parking brake shoe to .020 inch (.508 mm) less than drum measurement, Fig. .
- Reverse procedure to install.
E-Super Duty
E-450 & E-550
- Raise and support vehicle.
- Remove clevis pin and disconnect adjusting clevis from parking brake lever.
- Loosen jam nut several turn and position parking brake lever in applied position.
- Tighten or loosen...
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