2003 Mercury Grand Marquis Brake Service (ONLINE REPAIR MANUALS)

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...

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...

Battery Ground Cable

Prior to service, dis...

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

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

If caliper was removed when installing new components, clean all components in alcohol, then wipe dry using lint-free cloths. Using an air hose, blow out drilled passages and bores. Inspect dust boots for punctures or tears. If punctures or tears are evident, install new boots during assembly.

Inspect piston bores in both housings for scoring or pitting. Bores showing light scr...

On models with anti-lock brakes, the brake hydraulic 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

Removal

• Remove brake fluid until reservoir is half full.
• On models equipped with air suspension, turn air suspension service switch to Off position.
• On all models, raise and support front of vehicle, then remove ...

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 ...