2006 Mercury Milan Brake Service (ONLINE REPAIR MANUALS)

Brake Roughness

Thickness Variation

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

Lateral Runout

Excessive lateral runout of braking disc may cause a knocking back of the pistons, possibly creating increased pedal travel and vibration when brakes are applied.

Wheel Bearing Looseness

Replace whee...

Master Cylinder

Crown Victoria, Grand Marquis, Marauder, Mustang & Town Car

• Depress brake pedal several times to exhaust system vacuum.
• Disconnect master cylinder brake lines and electrical connectors.
• Disconnect hydraulic control unit supply hose at master cylinder. Secure hose aside.
• Remove two mounting bolts, then secure proportioning valve and tubes aside.
• Remove mounting nuts and master cylinder.
• Reverse procedure to install.

Focus

• Disconnect electrical connector and remove filler cap.
• Raise and support vehicle, remove front tire and wheel assemblies.
• Drain brake fluid into suit...

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

Removal

• Remove rear disc brake caliper as outlined under . Do not disconnect flexible hose unless caliper requires service.
• Support caliper with suitable wire or tie strap so flexible hose is not stretched or twisted.
• Remove rear disc support bracket to wheel knuckle bolts.
• Remove rear disc support bracket and brake shoes and linings.
• Remove two nuts and rotor.

Installation

• If installing new rotor, remove protective coating from rotor with suitable carburetor cleaner.
• Lubricate rear hub pilot diameter wi...

• Attach a rubber drain hose to bleeder screw of clutch master cylinder, then submerge free end of hose in a container partially filled with clean brake fluid.
• Slowly pump clutch pedal to floor several times and hold it.
• With clutch pedal held to floor,...

Parking Brake

Crown Victoria, Grand Marquis, Marauder & Town Car

• Apply parking brake control fully with 100 lbs., foot pedal effort, then release brake control.
• Place transmission in Neutral position, then raise and support vehicle.
• With parking brake control in Off position, grasp pensioner around housing.
• Unlock clip by pulling downward with suitable hook tool place into rounded end of clip and support pensioner.
• Tensioner spring will take up cable slack and load cables, while holding pensioner, lock clip by pushing up on bottom of clip. If clip does not slide up move assembly slightly ...

Replacement

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

Removal

• Raise and support rear of vehicle, then remove tire and wheel assembly.
• Disconnect brake hose from caliper.
• Remove retaining clip and disconnect parking brake cable from lever arm.
• Remove pinch bolts using open end wrench to hold slider pin in position.
• Lift caliper from anchor plate, then remove slider pins and boots.

Installation

• Apply suitable silicone dielectric compound to slider pins and inside of boots.
• Place slider pins and boots on anchor plate, then position caliper on ancho...