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Rear Disc Brake System Ford Five Hundred I

Mechanical - Hydraulic 1 illustration ~743 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
Brake disc minimum thickness9.5 mm (0.37 in)
Minimum thickness to machine the brake disc10.1 mm (0.39 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)

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

DescriptionNm
Bleeder screw10
Brake caliper anchor plate bolts110
Brake caliper bolts31
Brake disc screw21
Brake disc shield bolts14
Brake flexible hose25
Brake line fitting17

TORQUE SPECIFICATIONS

The brake pads have an adhesive backing that adheres to the brake caliper to reduce brake shudder and noise. The use of parts cleaners breaks down the adhesive and causes the brake pads to release from the brake caliper.

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

The brake disc is a non-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 wheel knuckle and is held in place by 3 screws. It protects the 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 2

Scheme 2: Disc Brake System - Exploded View
Scheme 2: Disc Brake System - Exploded View
  1. For additional information, refer to the procedures below.

Special Tool(s)

SPECIAL TOOL - BRAKE PADS Rear Caliper Piston Adjuster 206-026 (T87P-2588-A)

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 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. Check the brake fluid level in the brake fluid reservoir. If required, remove fluid until the brake master cylinder reservoir is half full.
  3. Remove the brake caliper bolts.
  4. Using hand force and a rocking motion, separate the brake caliper from the anchor plate. Position the brake caliper aside. Support the caliper with mechanic's wire.
  5. Remove and discard the brake pads and spring clips from the brake caliper anchor plate.
  6. 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.

Installation

  1. Using the special tool, compress the brake caliper piston into its cylinder.
  2. Clean the residual adhesive from the brake caliper fingers and pistons using the specified brake parts cleaner.
  3. Install the new spring clips and brake pads.
  4. Position the brake caliper and install the 2 bolts. Tighten to 31 Nm (23 lb-ft).
  5. If necessary, fill the brake fluid reservoir with clean specified brake fluid.
  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.
ItemSpecification
High Performance DOT 3 Motor Vehicle Brake Fluid PM-1 (Canada CPM-1)ESA-M6C25-A or WSS-M6C62-A

MATERIAL SPECIFICATION - BRAKE CALIPER

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. Remove the brake pads. For additional information, refer to «BRAKE PADS»(/ford/five-hundred/i-2004-2007/remont/mechanical-hydraulic/#rear-disc-brake-system) .
  2. Disconnect the parking brake cable from the subframe bracket and the caliper. Position the parking brake cable aside.
  3. Clean and inspect the disc brake caliper. If leaks or damaged boots are found, install a new disc brake caliper.
  4. Disconnect the brake line fitting from the brake flexible hose. To install, tighten to 17 Nm (13 lb-ft).
  5. Remove the retainer clip from the brake flexible hose.
  6. To install, reverse the removal procedure. Bleed the caliper. For additional information, refer to «BRAKE SYSTEM-GENERAL INFORMATION»(/ford/five-hundred/i-2004-2007/remont/brakes-control-systems/#brake-system-general-information) .

Removal and Installation

  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 anchor plate bolts and discard. Position the brake caliper anchor plate aside. To install, tighten to 110 Nm (81 lb-ft).
  3. Remove and discard the brake disc screw. To install, tighten to 21 Nm (15 lb-ft).
  4. Remove the brake disc.
  5. To install, reverse the removal procedure, using 2 new brake caliper anchor plate bolts.
  1. Remove the brake disc. For additional information, refer to «BRAKE DISC»(/ford/five-hundred/i-2004-2007/remont/mechanical-hydraulic/#rear-disc-brake-system) .
  2. Remove the 3 bolts and the brake disc shield. To install, tighten to 14 Nm (10 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. Disconnect the brake line fitting from the brake flexible hose. To install, tighten to 17 Nm (13 lb-ft).
  3. Remove the retaining clip from the brake flexible hose.
  4. Disconnect the brake flexible hose from the brake caliper. To install, tighten to 25 Nm (18 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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