2004 Ford Mustang Brake Service (ONLINE REPAIR MANUALS)

Power brake operation concerns should be handled as if two separate systems exist.

• Inspect for faults in hydraulic system first.
• If hydraulic system is satisfactory, inspect power brake circuit.
• Press brake pedal firmly and then start engine.
• Pedal should fall away slightly and less pressure should be needed to maintain pedal in any position.
• Install of suitable pressure gauge in brake hydraulic system.
• Record pressure with engine off and power unit not operating.
• Maintain pedal height, start engine and record measurement.
• There should be substantial pressure increase in second measurem...

This procedure has been revised by a Technical Service Bulletin.

On Sable and Taurus models, the disc rotor is a hat section-type of composite steel and cast iron. A Rotunda Rotor Mounting Adapter tool No. 054-00032, or equivalent, is required for use on the brake lathe for refinishing. Failure to use the adapter will result in gouging the brake disc, making it unfit for use.

On Sable and Taurus models, if service is required, install the new full cast front disc rotors, part No. F10Y-1125-B, in pairs only. Never install a full cast rotor on one side of the vehicle with a composite...

On models with anti-lock brakes, the brake system power booster must be depressurized before disconnecting any hydraulic lines or fittings. Depressurize the system by pumping the brake pedal at least 25 times with the ignition in the Off position.

After performing any service work, obtain a firm brake pedal before moving the vehicle.

Five Hundred, Freestyle, Fusion Milan, MKZ, Montego, Mustang, Sable, Taurus & Zephyr

Removal

• On models equipped with air suspension, turn service switch Off position.
• On all models, raise and support rear of vehicle, then remove tire and wheel assembly...

This procedure has been revised by a Technical Service Bulletin.

On Sable and Taurus models, the disc rotor is a hat section-type of composite steel and cast iron. A Rotunda Rotor Mounting Adapter tool No. 054-00032, or equivalent, is required for use on the brake lathe for refinishing. Failure to use the adapter will result in gouging the brake disc, making it unfit for use.

On Sable and Taurus models, if service is required, install the new full cast front disc rotors, part No. F10Y-1125-B, in pairs only. Never install a full cast rotor on one side of the vehicle with a composite...

Whenever new brake components are installed in the hydraulic system, it is recommended that the entire hydraulic system be thoroughly flushed with clean brake fluid.

It may sometime become required to flush out the system due to the presence of mineral oil, kerosene, gasoline, etc., which will cause swelling of rubber piston cups and valves and render them inoperative.

Flushing is performed at e...

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...