2007 Ford Five Hundred Brake Service (ONLINE REPAIR MANUALS)

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...

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...

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...

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...

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...

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 ...