2006 Mercury Milan Brake Service (ONLINE REPAIR MANUALS)

Master Cylinder

Disassemble

• Clean outside of master cylinder thoroughly. Drain brake fluid from master cylinder into suitable container.
• Remove stop bolt and pressure control valves.
• Pry up and remove reservoir from master cylinder body.
• Remove fluid control valve.
• Depress primary piston and remove snap ring from retaining groove at open end of bore.
• Remove primary and secondary piston assemblies from master cylinder. If secondary piston does not come out, apply air pressure to secondary outlet port to remove.

Inspection

• Wash components in clean brake fluid only. Use an air hose to bl...

Bendix Diaphragm System

These units are of the vacuum suspended system. Some units are of the single diaphragm system, while others are of the tandem diaphragm system. Both single piston and double piston or split system master cylinders are used.

The vacuum suspended diaphragm system units utilize engine manifold vacuum and atmospheric pressure for its power. It consists of three basic elements combined into a single power unit. The three basic elements of the single diaphragm system are:

• Vacuum power section which includes front and rear shell, power diaphragm, return spring and push...

Remove wheels and inspect brake disc, calipers and linings.

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 scratches or corrosion can usually be cleaned with...

Power Brake Booster

The diaphragm-type power brake booster is a self-contained unit, mounted on the firewall. The booster uses engine intake manifold vacuum and atmospheric pressure for its power. Other than the power brake booster check valve, the booster is serviced only as an assembly. The booster must be replaced if it becomes damaged or inoperative.

Brake Master Cylinder

The brake master cylinder consists of a fluid reservoir, reservoir control valve and a fluid level indicator. The fluid level indicator is located inside the brake master cylinder reservoir and replaces the previo...

Brake System Bleed

Manual

The primary and secondary (front and rear) hydraulic brake systems are individual systems and are bled separately. Bleed longest tube first on individual system being serviced. During complete bleeding operation, do not allow the master cylinder reservoir to run dry. Never reuse brake fluid that has been drained from hydraulic system or has been allowed to stand in an open container for an extended period of time.

• To bleed brake system, position a suitable box wrench on bleeder fitting on brake wheel cylinder. Attach rubber drain hose to bleeder fitting.
• Sub...

Power Booster, Replace

Crown Victoria, Grand Marquis, Marauder & Town Car

• Disconnect fluid level sensor connector.
• Position speed control cable aside.
• Disconnect power brake booster check valve.
• Remove brake master cylinder mounting nuts.
• Remove wiring harness bracket and position aside.
• Remove brake master cylinder and position aside.
• Remove push-pins and instrument close-out panel.
• Remove stoplight switch retaining pin.
• Slide stoplight switch and booster push rod off brake pedal pin.
• Remove mounting nuts and power brake booster.
• Reverse procedure to install. Torque mounting nuts ...