2006 Mercury Grand Marquis Brake Service (ONLINE REPAIR MANUALS)

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...

This system operates on the same principles as conventional front and rear split systems using primary and secondary master cylinders moving simultaneously to exert hydraulic pressure on their respective systems, Fig. .

The hydraulic brake lines on this system, however, have been diagonally split front to rear (left front to right rear and right front to left rear) in place of separate lines to the front and rear wheels.

In the event of a system failure this would cause the remaining good system to do all the braking on one front wheel and the opposite rear wheel, thus maintaining 50%...

Replacement

On models with anti-lock brakes, the brake booster system 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.

Crown Victoria, Five Hundred, Freestyle, Fusion, Grand Marquis, LS, Marauder, Milan, MKZ, Montego, Sable, Taurus, Thunderbird, Town Car & Zephyr

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

• On models equipped with air suspension, turn air suspension service switch...

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...

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...