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Front Disc Brake System Ford Five Hundred I

Mechanical - Hydraulic 1 illustration ~1138 words

GENERAL SPECIFICATIONS

ItemSpecification
Brake Pads
Brake pad minimum thickness3.0 mm (0.118 inch)
Brake pad maximum thickness variation (pad-to-pad)2.0 mm (0.079 inch)
Brake pad maximum taper wear (in any direction)3.0 mm (0.118 inch)
Brake Disc
Front brake disc minimum thickness26 mm (1.02 in)
Minimum thickness to machine front brake disc27.1 mm (1.06 in)
Lubricant
High Performance DOT 3 Motor Vehicle Brake Fluid PM-1 (Canada CPM-1)ESA-M6C25-A or WSS-M6C62-A
Metal Brake Parts Cleaner PM-4 (Canada CPM-4)
High Temperature Nickel Anti-Seize Lubricant XL-2 (Canada CXG-2-B)ESE-M12A4-A
Penetrating and Lock Lubricant XL-1

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

DescriptionNm
Bleeder screw11
Brake caliper anchor plate bolts100
Brake caliper bolts60
Brake caliper flow bolt (lubricated)30
Brake disc screw12
Brake disc shield bolts11
Brake flexible hose bracket bolt30
Brake line fittings18

TORQUE SPECIFICATIONS

CAUTIONWhen the brake pads are separated from the brake caliper, new brake pads must be installed. The brake pads are one-time use only.
CAUTIONLeaving the residual adhesive will increase the taper wear leading to brake noise, drag and roughness.

The brake pads have an adhesive backing that adheres to the brake caliper to reduce brake shudder and noise. Use the brake parts cleaner to remove the residues of the adhesive on the caliper pistons before installing the new pads.

The brake caliper is mounted to the brake caliper anchor plate, which is bolted to the wheel knuckle. The brake caliper anchor plate locating and guide pins allow the dual piston brake caliper to move as the brake pads wear.

The brake disc is a ventilated full-cast design. The brake disc is removed and installed by removing the brake caliper and anchor plate as an assembly.

The brake disc shield is mounted to the front wheel knuckle and is held in place by 3 screws. It protects the front wheel bearings and inner surface of the brake disc from damaging road debris.

The brake pads are housed in the brake caliper anchor plate assembly and are of a non-asbestos composition.

Scheme 1

Scheme 1: Disc Brake System - Exploded View
Scheme 1: Disc Brake System - Exploded View
  1. For additional information, refer to the procedures below.

Material

ItemSpecification
High Performance DOT 3 Motor Vehicle Brake Fluid PM-1 (Canada CPM-1)ESA-M6C25-A or WSS-M6C62-A
Metal Brake Parts Cleaner PM-4 (Canada CPM-4)

MATERIAL SPECIFICATION - BRAKE PADS

Removal

WARNINGUse of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury.
WARNINGBrake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury.
CAUTIONBrake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.
CAUTIONDo not allow the brake fluid to come in contact with the adhesive backing on the brake pads. If brake fluid is spilled onto the brake pads new pads must be installed.
CAUTIONUse only specified brake parts cleaner. Use of other cleaners may leave a residue on the brake caliper preventing the brake pads adhesive surface from bonding with the brake caliper.
  1. Check the brake fluid level in the brake master cylinder reservoir. If required, remove the fluid until the brake master cylinder reservoir is half full.
  2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
  3. Using the large C-clamp, compress the pistons into the caliper housing. Position one end of the C-clamp on the outer pad between the caliper fingers, the other end on the caliper housing. During this process, the outer brake pad will separate from the caliper housing.
  4. Remove the 2 brake caliper guide pin bolts.
  5. Separate the inner brake pad from the caliper.
  6. Position the caliper aside. Support the caliper using mechanic's wire.
  7. Remove the 2 brake pads and spring clips from the brake caliper anchor plate. Discard the retraction clips.
  8. Inspect the brake caliper for leaks or damage. Install a new brake caliper if required.
  9. Inspect the brake caliper anchor plate. Install a new brake caliper anchor plate if required. Inspect the guide pins and boots for binding or damage, replace as necessary.

Installation

  1. Clean the residual adhesive from the brake caliper-to-brake pad mating surfaces (brake caliper piston and the opposing caliper housing fingers) using brake parts cleaner.
  2. Install the new spring clips and brake pads to the brake caliper anchor plate.
  3. Position the brake caliper onto the brake caliper anchor plate and install the 2 caliper guide pin bolts. Tighten to 60 Nm (44 lb-ft).
  4. If necessary, fill the brake master cylinder reservoir with clean brake fluid.
  5. With the vehicles engine running, apply 89-133 N (20--30 lb) of pressure on the brake pedal for one minute to make sure the brake pads adhere to the brake caliper before any contamination can be introduced.
  6. Test the brakes for normal operation.
ItemSpecification
High Performance DOT 3 Motor Vehicle Brake Fluid PM-1 (Canada CPM-1)ESA-M6C25-A or WSS-M6C62-A
Metal Brake Parts Cleaner PM-4 (Canada CPM-4)

MATERIAL SPECIFICATION - BRAKE CALIPER

WARNINGUse of any other than approved DOT 3 brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury.
WARNINGBrake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury.
CAUTIONBrake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.
  1. Check the brake fluid level in the brake master cylinder reservoir. If required, remove the fluid until the brake master cylinder reservoir is half full.
  2. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
  3. Using the large C-clamp, compress the pistons into the caliper housing. Position one end of the C-clamp on the outer pad between the caliper fingers, the other end on the caliper housing. During this process, the outer brake pad will separate from the caliper housing.
  4. Remove the brake pads. For additional information refer to «BRAKE PADS»(/ford/five-hundred/i-2004-2007/remont/mechanical-hydraulic/#front-disc-brake-system) .
  5. Remove the brake caliper flow bolt and position the brake hose aside. Discard the copper washers.
  6. Remove the brake caliper.
  1. Clean the residual adhesive from the brake caliper-to-brake pad mating surfaces using brake parts cleaner.
  2. Install the new spring clips and brake pads to the brake caliper anchor plate. For additional information, refer to «BRAKE PADS»(/ford/five-hundred/i-2004-2007/remont/mechanical-hydraulic/#front-disc-brake-system) .
  3. Position the brake hose and install the brake caliper flow bolt. Install new copper washers. Tighten to 30 Nm (22 lb-ft).
  4. Bleed the brakes. For additional information, refer to «BRAKE SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/brakes-control-systems/#brake-system-general-information) .
  5. With the vehicles engine running, apply 89--133 N (20--30 lb) of pressure on the brake pedal for one minute to make sure the brake pads adhere to the brake caliper.
  6. With the vehicle engine running, apply 89--133 N (20--30 lb) of pressure on the brakes for approximately 1 minute, to make sure the brake pads adhere to the caliper before any contamination can be introduced.
  7. Test the brakes for normal operation.
  1. Remove the brake pads. For additional information, refer to «BRAKE PADS»(/ford/five-hundred/i-2004-2007/remont/mechanical-hydraulic/#front-disc-brake-system) .
  2. Remove and discard the 2 brake caliper anchor plate bolts and remove the brake caliper anchor plate. Make sure the steering stop is supported when the brake caliper anchor plate bolts are removed.
  3. Inspect the brake caliper anchor plate assembly. Check the guide pins and boots for binding or damage. Install a new brake caliper anchor plate if it is worn or damaged.
  1. Position the brake caliper anchor plate and steering stop on the wheel knuckle and install 2 new bolts. Tighten to 100 Nm (74 lb-ft).
  2. Install the brake pads. For additional information, refer to «BRAKE PADS»(/ford/five-hundred/i-2004-2007/remont/mechanical-hydraulic/#front-disc-brake-system) .
ItemSpecification
High Temperature Nickel Anti-Seize Lubricant XL-2 (Canada CXG-2-B)ESE-M12A4-A
Penetrating and Lock Lubricant XL-1
Metal Brake Parts Cleaner PM-4 (Canada CPM-4)

MATERIAL SPECIFICATION - BRAKE DISC

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
  2. Remove and discard the 2 bolts and position the brake caliper and anchor plate assembly aside.
  3. Remove and discard the brake disc screw.
  4. Remove the brake disc.
  1. Clean any rust or foreign material from brake disc and wheel hub. Use brake parts cleaner to clean the front brake disc and hub surfaces.
  2. Apply a thin coat of anti-seize lubricant to the hub flange.
  3. Install the brake disc.
  4. Install a new brake disc screw. Tighten to 12 Nm (9 lb-ft).
  5. Position the brake caliper and brake caliper anchor plate assembly and install 2 new bolts. Tighten to 100 Nm (74 lb-ft).

Removal and Installation

  1. Remove the brake disc. For additional information, refer to «BRAKE DISC»(/ford/five-hundred/i-2004-2007/remont/mechanical-hydraulic/#front-disc-brake-system) .
  2. Remove the 3 bolts and the brake disc shield. To install, tighten to 11 Nm (8 lb-ft).
  3. To install, reverse the removal procedure.
ItemSpecification
High Performance DOT 3 Motor Vehicle Brake Fluid PM-1 (Canada CPM-1)ESA-M6C25-A or WSS-M6C62-A

MATERIAL SPECIFICATION - BRAKE FLEXIBLE HOSE

WARNINGUse of any other than approved DOT 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative. Failure to follow these instructions may result in personal injury.
WARNINGBrake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if irritation persists. If taken internally, drink water and induce vomiting. Get medical attention immediately. Failure to follow these instructions may result in personal injury.
CAUTIONBrake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a painted or plastic surface, immediately wash it with water.
CAUTIONDo not allow the brake fluid to come in contact with the adhesive backing on the brake pads. If brake fluid is spilled onto the brake pads new pads must be installed.
CAUTIONUse only specified brake parts cleaner. Use of other cleaners may leave a residue on the brake caliper preventing the brake pads adhesive surface from bonding with the brake caliper.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/five-hundred/i-2004-2007/remont/hoistjack/#jacking-lifting) .
  2. Remove the brake caliper flow bolt and discard the 2 copper washers. To install, tighten to 30 Nm (22 lb-ft).
  3. Disconnect the brake line fitting from the brake flexible hose. To install, tighten to 18 Nm (13 lb-ft).
  4. Remove the bolt and the brake flexible hose. To install, tighten to 30 Nm (22 lb-ft).
  5. To install, reverse the removal procedure. Bleed the system. For additional information, refer to «BRAKE SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/brakes-control-systems/#brake-system-general-information) .

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