2003 Ford Taurus Brake Service (ONLINE REPAIR MANUALS)

Service Brakes

Although the brakes are self-adjusting, an initial adjustment will be required after a brake repair. This adjustment is performed as follows:

• Determine inside diameter of brake drum surface using brake shoe gauge tool No. D81L-1103-A, or equivalent. Adjust brake shoe diameter to fit gauge. Hold automatic adjusting lever out of engagement while rotating adjustin...

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...

• Inspect components for damage and unusual wear. Replace as required.
• Inspect wheel cylinders. Boots which are torn, cut, or heat damaged indicate need for wheel cylinder replacement. Fluid spilling from boot center hole, or wetness around wheel cylinder ends indicates cup leakage and need for wheel cylinder replacement. A small amount of fluid is always present and is considered normal, acting as lubricant for cylinder pistons.
• Inspect backing plate for evidence o...

Brake Roughness

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 the edge of the disc. If thickness measurements vary by more than .0005 inch, replace the rotor.

Excessive later...

Brake System Bleed

Refer to "Hydraulic Brake Systems" for bleed procedure.

Component Replacement

Hydraulic Control Unit

Continental

• Remove engine air cleaner and air cleaner outlet tube.
• Disconnect connector attaching anti-lock brake module to wire harness.
• Remove tubes from inlet ports of pump motor and tubes from outlet ports of brake pressure control valve block. Plug each port to prevent brake fluid from spilling on paint and wiring.
• Remove HCU to mounting bracket retaining nuts, then tip rear of HCU up and pull rearward to slide forward mounting pins out of the retaining grommets.
• Remo...

Pushrod

Proper adjustment of the master cylinder pushrod is necessary to ensure proper operation of the power brake system. A pushrod that is too long will prevent the master cylinder piston from completely releasing hydraulic pressure, eventually causing the brakes to drag. A pushrod that is too short will cause excessive brake pedal travel and cause groaning noises to come from the booster when the brakes are applied. A properly adjusted pushrod that remains assembled to the booster with which is was matched during production should not require service adjustment. However, if the b...