2003 Ford Thunderbird Brake Service (ONLINE REPAIR MANUALS)

Inspection & Verification

• Verify ABS concern by applying brakes under varying conditions.
• Verify stoplamps are working properly.
• Verify "PRNDL" indicator on instrument cluster is working properly.
• Visually inspect the following for mechanical or electrical damage:
• Underhood auxiliary junction box fuses.
• Central junction box fuses.
• Anti-lock brake sensor indicators and sensors.
• Base brake concerns.
• Tire pressure.
• Hydraulic control unit.
• Tire size, or mismatched tires.
• ABS/stability assist control module.
• Brake booster vacuum hose.
• Ford specified steering and suspension components.
• Steering wheel ...

Remove wheels and inspect brake disc, caliper and linings. Inspect wheel bearings and repack if required.

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

If caliper is removed when installing new components, clean all components in alcohol, then wipe dry using lint-free cloths. Blow out drilled passages and bores with compressed air. Inspect dust boots for punctures or tears, replace as required.

Inspect piston bores in both housings for scoring or pitting. Bores showing light scratches or corrosion can be cleaned with crocus clo...

Replacement

Continental, Cougar, Mustang, Sable & Taurus

Removal

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

Single Piston Calipers

The caliper assembly consists of a pin sliding caliper housing, inner and outer shoe and lining assemblies and a single piston, Figs. and . The caliper slides on two pins which also act as attaching bolts between caliper and the combination anchor plate and spindle. The outer brake shoe and lining assembly is longer than the inner brake shoe and lining assembly. Inner and outer shoe and lining assemblies are attached to the caliper by spring clips riveted to the shoe surfaces. The inner shoe is attached to the caliper by installing the spring clip to the insid...

Pushrod

Proper adjustment of the master cylinder pushrod is necessary to ensure proper operation of the power brake system. A pushrod that is too long will prevent the master cylinder piston from completely releasing hydraulic pressure, eventually causing the brakes to drag. A pushrod that is too short will cause excessive brake pedal travel and cause groaning noises to come from the booster when the brakes are applied. A properly adjusted pushrod that remains assembled to the booster with which is was matched during production should not require service adjustment. However, if the b...

ABS Control Module

On models less stability control, an ABS control module is used to control ABS and/or traction control. The ABS module is self monitoring. When ignition switch is turned to the run position, the ABS control module performs a preliminary electrical inspection. When vehicle speed reaches 12 mph, the pump motor is actuated for ^1/2 second. A fault in the ABS system will cause ABS operation to deactivate and the yellow ABS warning indicator to illuminate. Normal power assisted braking will still remain available.

When the ABS control module is replaced, it is required to...