1994 Mercury Sable Brake Service (ONLINE REPAIR MANUALS)

CALIPER, REPLACE

The hydraulic system must be depressurized before disconnecting any hydraulic lines or fittings. Depressurize the system by pumping the brake pedal a minimum of 25 times with the ignition switch in the OFF position.

EXCEPT ASPIRE, CAPRI, ESCORT, FESTIVA, PROBE & TRACER

Before removing calipers, mark lefthand and righthand calipers so they can be installed in the same position.

• On 1994 Continental, Sable and Taurus models, turn air suspension service switch off.
• On all models, raise and support front of vehicle, then remove wheel and tire assembly.
• Loosen brake tube fi...

CAPRI

Removal

• Raise and support vehicle, then remove wheel and tire assembly.
• Using chisel, unstake and remove halfshaft nut and washer. Discard nut and washer.
• Remove brake pads and caliper from steering knuckle as described under "Brake Pad Service."
• Support caliper with wire strung from coil spring. Do not disconnect brake line from caliper.
• Using tie rod end separator tool No. T85M-3395-A, or equivalent, disconnect tie rod end from steering knuckle.
• Remove ball joint pinch bolt, then separate control arm from steering knuckle.
• Remove steering knuckle to strut assembly bolts.
• Using knuck...

Pressure bleeding is recommended for all hydraulic disc brake systems.

The disc brake hydraulic system can be bled manually or with pressure bleeding equipment. The brake pedal will require more pumping and frequent checking of fluid level in master cylinder during bleeding operation.

Do not use brake fluid drained from the hydraulic system when bleeding the brakes. Be sure the disc brake pistons are returned to their normal positions and the shoe and lining assemblies are properly seated. Before driving the vehicle, check brake operation to be sure a firm pedal has been obtain...

Remove wheels and inspect brake disc, caliper and linings. The wheel bearings should be inspected at this time and repacked if necessary. Do not get any grease on the linings.

If the caliper is cracked or fluid leakage through the casting is evident, it must be replaced as a unit.

Should it become necessary to remove the caliper when installing new parts, clean all parts in alcohol, then wipe dry using lint-free cloths. Using an air hose, blow out drilled passages and bores. Check dust boots for punctures or tears. If punctures or tears are evident, install new boots during assembly.

In...

The anti-lock system (ABS), Fig. , controls each brake separately. The brake pedal force required to engage the system may vary with road surface conditions. A dry surface will require a high force, while a slippery surface will require a much less force. During system operation, the driver will sense a slight brake pedal pulsation accompanied by a rise in brake pedal height and a clicking sound. The pedal effort and pedal feel during normal braking are similar to a conventional power brake system.

SYSTEM COMPONENTS

Vacuum Booster

The diaphragm type brake booster is self-contained and ...

Brake System Bleed

• Disconnect 55-pin plug from ABS module (ECU), then attach anti-lock breakout box/bleeding adapter tool No. T90P-50-ALA, or equivalent, to wiring harness 55-pin plug.
• Place bleed/harness switch in bleed position.
• Turn ignition to On position. Red Off light should turn on.
• Push motor button on adapter down to start pump motor. Red Off light will turn off and green On light will turn on. Pump motor will run for 60 seconds once motor button is pushed.
• If pump motor is turns off before 60 seconds has elapsed, push abort button and pump motor will turn off.
• After 20 second...