2004 Mercury Sable Brake Service (ONLINE REPAIR MANUALS)

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...

Safety Precautions

When working on or around brake assemblies, care must be taken to prevent breathing asbestos dust, as many manufacturers incorporate asbestos fibers in the production of brake linings. During routine service operations the amount of asbestos dust from brake lining wear is at a low level, due to a chemical breakdown during use. A few precautions will minimize exposure. Do not sand or grind brake linings unless suitable local exhaust ventilation equipment is used to prevent excessive asbestos exposure.

• Wear suitable respirator approved for asbestos dust use during all...

Dual Piston Calipers

The caliper consists of a sliding bridge type caliper housing with dual pistons, caliper mounting frame and inner and outer friction pad assemblies, Figs. and . The caliper is located into and slides on the anchor frame by its thrust face and a locating pin and clip. The friction pads are retained into the anchor frame by the caliper sliding bridge assembly and use an anti-rattle spring clip to reduce brake noise. The friction pads are retained into the sliding bridge assembly by clips located on the back of the friction pad.

Lefthand and righthand caliper and in...

Disc brake service is critical because of 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 promote long lining life and equal lining wear of both the lefthand and righthand brakes.

Do not attempt to refinish the rubbing surfaces unless precision equip...

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

Sliding caliper rear disc brakes are used on these models. The caliper is basically the same as the larger front wheel caliper. However, a parking brake mechanism and a larger inner brake shoe anti-rattle spring have been added.

The parking brake lever, located at the rear of the caliper, is actuated by a cable system similar to rear drum brake applications. When the parking brake is applied, the cable rotates the lever and operating shaft, driving the caliper piston and brake shoe assembly again...

Pressure bleeding is recommended for all hydraulic brake systems. Ensure all dirt and contaminants are removed from master cylinder area prior to removing reservoir cap.

To prevent air from the pressure tank getting into the lines, do not shake the tank while air is being added to the tank or after it has been pressurized. Set the tank in the required location, bring the air hose to the tank, and do not move it during the bleeding operation. The tank should be kept at least one-third full.

On vehicles equipped with disc brakes and master cylinders without proportioners or press...