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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+.
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+.
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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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+.
Anti-Lock Brakes -> Villager -> Diagnosis & Testing -> Accessing Diagnostic Trouble Codes -> Clearing Diagnostic Trouble Codes -> Diagnostic Tests -> Diagnostic Trouble Code Interpretation -> Pinpoint Tests -> Quick Test
Vehicle: 2002 Mercury Villager 3.3 V6 GAS
Accessing Diagnostic Trouble Codes
- Connect New Generation STAR (NGS) Tester tool No. 007-00500, or equivalent, to Data Link Connector (DLC) located beneath central junction box.
- Select vehicle.
- If NGS Tester does not communicate with vehicle, proceed as follows:
- Ensure program card is properly installed.
- Inspect connections to vehicle.
- Ensure ignition switch is in On position.
- If NGS Tester still does not communicate with vehicle, refer to NGS Tester manual.
- Follow NGS Tester instructions to retrieve DTC's.
Diagnostic Trouble Code Interpretation
Refer to Fig. for diagnostic tro...
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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+.
Drum Brakes -> Escape, Villager & Windstar -> Adjustments -> Parking Brake -> Service Brake
Vehicle: 2002 Mercury Villager 3.3 V6 GAS
Service Brake
- Raise and support vehicle. Ensure parking brake is released.
- Remove rubber access plug from backing plate.
- Slowly rotate rear wheel while gradually increasing length of adjuster assembly by rotating adjusting screw using brake adjustment tool No. D91L-1103-C, or equivalent.
- In...
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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 -> Inspection -> Brake Bleed -> Brake Disc Service -> Brake Linings -> Brake Roughness -> Caliper Inspection -> General Precautions
Vehicle: 2002 Mercury Villager 3.3 V6 GAS
Brake Linings
Remove both front wheels and inspect the brake discs, calipers and linings. (Wheel bearings should be inspected at this time and repacked if required).
Do not get any oil or grease on the linings. It is recommended that both front wheel sets be replaced whenever a respective shoe and lining is worn or damaged. Inspect and, if required, replace rear brake linings also.
If the caliper is cracked or fluid leakage through the casting is evident, it must be replaced as a unit.
Brake Roughness
The most common cause of brake chatter on disc brakes is a variation in thickness of the...
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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 -> Troubleshooting -> Brake Noise -> Brake Pedal Eases Down Slowly -> Brake Pedal Goes Down Fast -> Brakes Drag -> Brakes Lock Up During Light Brake Pedal Force -> Brakes Pull Or Drift -> Excessive Brake Pedal Effort -> Excessive Or Erratic Brake Pedal Travel -> Red Brake Warning Indicator Always On
Vehicle: 2002 Mercury Villager 3.3 V6 GAS
Brakes Pull Or Drift
- Tire air pressure.
- Wheel alignment.
- Brake pads, shoes or linings.
- Brake or suspension components.
Red Brake Warning Indicator Always On
- Instrument cluster.
- Warning indicator circuit.
- Parking brake.
- Brake fluid level.
Brake Pedal Goes Down Fast
- Brake fluid level.
- Air in system.
- Brake master cylinder fault.
- Normal RABS or ABS function.
Brake Pedal Eases Down Slowly
- Air in system.
- Brake master cylinder fault.
- Normal RABS or ABS function.
Brakes Lock Up During Light Brake Pedal Force
- Disc or drum brake component.
- Parking brake component...
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