Disc & Drum: Removal & Installation Ford Thunderbird X

REMOVAL & INSTALLATION

Removal

Raise and support vehicle. Remove front wheels. Disconnect and plug brake hose from caliper. Mark caliper for right or left installation reference. Remove flex brake hose from caliper. Remove caliper locating pins. Remove caliper. Note position of brake pads, shims and anti-rattle springs (if equipped) position and remove components.

Note. On Mustang, inner brake pads are stamped LH (left side) or RH (right side). Ensure pads are installed correctly.

Installation

Apply high-temperature grease to guide pins and insulators. Install brake pads. Ensure brake pads are installed correctly. If new brake pads have been installed, seat brake caliper piston in caliper bore. To complete installation, reverse removal procedure. Refill and bleed system. See BLEEDING BRAKE SYSTEM .

Note. On Mustang 2.3L, use NEW locating pins when installing brake pads.

Removal & Installation (Except Mark VII & Mustang)

1. Remove front brake caliper and pads. If caliper does not require service, removing brake hose from caliper is not necessary.
2. Using mechanic's wire, secure caliper out of way. See «FRONT BRAKE CALIPER & PADS»(ref-44055-S37144072622001011500000) . Remove rotor from hub assembly. If rotor is difficult to remove, spray rust penetrant on front and rear of rotor/hub mating surfaces.
3. Using a plastic hammer, strike rotor between studs. If rotor is still difficult to remove, use a 3-jawed puller. To install rotor, reverse removal procedure. Bleed brakes. See «BLEEDING BRAKE SYSTEM»(ref-44055-S07235802282001011500000) .

Removal & Installation (Mark VII & Mustang)

1. Raise and support vehicle. Remove front wheels. Remove front brake caliper and pads. See «FRONT BRAKE CALIPER & PADS»(ref-44055-S37144072622001011500000) . If caliper does not require service, removing brake hose from caliper is not necessary.
2. Using mechanic's wire, secure caliper out of way. Remove dust cap, cotter pin, lock nut, spindle nut, washer and outer bearing. Remove rotor and hub assembly. To install, reverse removal procedure. Adjust wheel bearings as necessary. See «FRONT WHEEL BEARINGS»(ref-44055-S10858865412001011500000) under ADJUSTMENTS. Bleed brakes. See «BLEEDING BRAKE SYSTEM»(ref-44055-S07235802282001011500000) .

Removal (Mark VII)

1. Raise and support vehicle. Remove rear wheels. Disconnect and plug brake hose from caliper. Remove parking brake cable retaining clip from brake caliper. Disconnect parking brake cable.
2. Using an open-end wrench, hold slider pin and remove slider pin pinch bolt. Lift caliper assembly away from anchor plate. Remove slider pins and boots from anchor plate. Remove brake pads and anti-rattle springs.

Installation (Mark VII)

1. When installing new brake pads, caliper piston must be properly retracted. Using Piston Remover (T87P-2588-A), rotate piston clockwise until piston is fully seated.
2. Ensure one of slots in piston face is positioned so it will engage nib on brake pad. (Scheme 2) Install brake pads, anti-rattle springs and brake caliper.
3. Ensure brake pads are properly positioned. Clean pinch bolt threads and apply one drop of Threadlock and Sealer (EOAC-16554-A). To complete installation, reverse removal procedure. Bleed brakes. See «BLEEDING BRAKE SYSTEM»(ref-44055-S07235802282001011500000). Adjust parking brake as necessary. See «PARKING BRAKE»(ref-44055-S06353333872001011500000) under ADJUSTMENTS.

Scheme 2

Removal (Cougar & Thunderbird)

1. Raise and support vehicle. Remove rear wheels. Disconnect and plug brake hose from caliper. Before disconnecting parking brake cable from caliper, cable tension must be released.
2. While supporting tensioner, remove retaining clip. see scheme 4 Have an assistant apply parking brake to its full on position. Reinstall cable retaining clip. Ensure locking lever is secure by rotating lever toward threaded rod.
3. Disconnect parking brake cable from caliper. Using an open-end wrench, hold slider pin and remove slider pin pinch bolt. Lift caliper assembly away from anchor plate. Remove slider pins and boots from anchor plate. Remove brake pads.

Installation (Cougar & Thunderbird)

1. When installing new brake pads, caliper piston must be properly retracted. Using Piston Remover (T87P-2588-A), rotate piston clockwise until piston is fully seated.
2. Ensure one of slots in piston face is positioned so it will engage nib on brake pad. (Scheme 2) Install brake pads. Install caliper. Ensure brake pads are properly positioned. Clean pinch bolt threads and apply one drop of Threadlock and Sealer (EOAC-16554-A).
3. To complete installation, reverse removal procedure. Bleed brakes. See «BLEEDING BRAKE SYSTEM»(ref-44055-S07235802282001011500000). Adjust parking brake. See «PARKING BRAKE»(ref-44055-S06353333872001011500000) under ADJUSTMENTS.

Remove brake caliper. See REAR BRAKE CALIPER & PADS . Remove caliper anchor plate (if equipped). Remove rotor retaining nuts and rotor. To install, reverse removal procedure. Bleed brakes. See BLEEDING BRAKE SYSTEM . Adjust parking brake as necessary. See PARKING BRAKE under ADJUSTMENTS.

1. Raise and support vehicle. Remove brake drum. If brake drum is difficult to remove, back-off brake self-adjuster. Install Brake Cylinder Clamp (D81L-1103-B) over ends of wheel cylinder pistons. Disconnect parking brake cable from brake lever. (Scheme 3)
2. Spread brake shoes over wheel cylinder. Remove brake shoe hold-down springs, retainers and pins. Remove remaining springs. Remove brake shoes and adjuster assembly. Disassemble parking brake lever from secondary brake shoe by removing retaining clip and spring washer.

Scheme 3

1. Apply light coating of Disc Brake Caliper Slide Grease (D7AZ-19590-A) to backing plate brake shoe contact areas. Assemble brake adjuster and stainless steel washer. Lubricate threads of adjusting screw and turn screw into pivot nut to limit of threads.
2. Back off adjuster screw 1/2 turn. Assemble parking brake lever to secondary shoe. Install spring washer and new retaining clip. Crimp clip until lever is securely fastened. Install parking brake cable to parking brake lever.
3. Attach secondary shoe on backing plate. Position primary shoe on backing plate and install lower retracting spring to brake shoes. Install adjuster assembly. Install adjuster lever.
4. Install upper retracting spring in slot on secondary shoe and slot in adjuster socket. Adjuster lever should contact star of adjuster assembly. Install brake anchor pins, springs and retainers. Adjust brake shoes and install drums. See «REAR BRAKE SHOES»(ref-44055-S30871634162001011500000) under ADJUSTMENTS. To complete installation, reverse removal procedure.

Removal (Mustang)

1. Raise and support vehicle. Release brake adjustment if necessary, and remove brake drum. Install Cylinder Clamp (D81L-1103-B) over wheel cylinder pistons. Remove shoe-to-anchor springs and unhook cable eye from anchor pin. Remove anchor plate. (Scheme 4)
2. Remove hold-down springs, shoes, adjusting screw, pivot nut, socket and automatic adjuster. Remove parking brake link spring and retainer. Disconnect parking brake cable from lever. After removing secondary shoe, disassemble parking brake lever from shoe by removing retaining clip and spring washer.

Scheme 4

Installation (Mustang)

1. Assemble parking brake lever to secondary shoe and secure with spring washer and retaining clip. Using high temperature grease, lubricate brake shoe contact points. Position shoes on backing plate and install hold-down springs.
2. Install parking brake link, spring and retainer. Back off parking brake adjustment and connect cable to brake lever. Install anchor pin plate. Place cable eye over anchor pin with crimped side toward drum.
3. Install primary shoe anchor spring. Install cable guide on secondary shoe web, with flanged hole fitted into hole in shoe web. Thread cable around anchor guide groove, NOT between guide and shoe web. Install secondary anchor spring. All parts should be flat on anchor pin.
4. Lubricate threads of adjusting screw and turn screw into pivot nut to limit of threads. Back off adjuster screw 1/2 turn and place socket on screw end. Install assembly between shoe ends, with adjusting screw toothed wheel nearest secondary shoe. NOTE: Brake shoe adjusting assemblies are not interchangeable from side to side. Socket end of adjusting screw is marked "R" for right or "L" for left.
5. Install cable hook in adjusting lever. Position hooked end of adjuster spring completely into large hole of primary shoe web. Connect loop end of spring to adjuster lever hole. Pull adjuster lever, cable and adjuster spring down and rearward, engaging pivot hook in large hole of secondary shoe web.
6. Ensure shoes are seated and centered on backing plate, and automatic adjuster is operating. Install drums. Bleed brakes. See «BLEEDING BRAKE SYSTEM»(ref-44055-S07235802282001011500000) . Check for proper brake operation.

Disconnect brake fluid level indicator connector. Disconnect hydraulic-brake lines from master cylinder. Remove master cylinder attaching nuts and remove master cylinder.

To install, reverse removal procedure. Bleed brake system. See BLEEDING BRAKE SYSTEM .

Removal (Cougar, Mustang 5.0L & Thunderbird)

1. Disconnect negative battery cable. Remove air cleaner (if necessary). Disconnect manifold vacuum hose from booster check valve. Disconnect brake lines from master cylinder. Remove master cylinder-to-brake booster nuts. Remove master cylinder.
2. From under dash, remove brakelight switch wiring connector. Remove brakelight retaining pin. Slide brakelight switch off brake pedal pin just enough for outer plate of brakelight switch to clear pin. Remove brakelight switch from pin. DO NOT damage switch during removal.
3. Remove booster-to-dash panel retaining nuts. Slide booster push rod, bushing and inner nylon washer off brake pedal pin. From under hood, move booster forward until booster studs clear firewall. Rotate front of booster inward (toward engine) and remove booster by raising until clear.

Installation (Cougar, Mustang 5.0L & Thunderbird)

To install, reverse removal procedure. Bleed brakes. See BLEEDING BRAKE SYSTEM .

Removal (Mustang 2.3L)

1. Disconnect negative battery cable. Disconnect accelerator cable from throttle body. Remove accelerator cable-to-accelerator shaft bracket screws and remove cable from bracket. Remove 2 accelerator shaft bracket-to-manifold screws, and rotate bracket toward engine. WARNING: Fuel system is under pressure and must be bled before disconnecting quick-connect fittings.
2. Remove fuel cap to release fuel tank pressure. Using EFI Pressure Gauge (T80L-9974-B), release fuel pressure from relief valve. Relief valve is located on fuel supply manifold.
3. Disconnect 2 manifold injector connectors located near oil dipstick retaining bracket. Disconnect fuel inlet and return hoses at fuel supply manifold. Remove dipstick bracket. Remove wiper motor. Remove vacuum hoses over brake booster at dash panel vacuum tee.
4. Remove bolt holding clutch cable stand, and move aside. If equipped with speed control, move speed control cable to clear booster. Disconnect manifold vacuum hose from booster check valve. Remove brake lines from master cylinder. Remove master cylinder-to-booster nuts and master cylinder.
5. From inside vehicle, remove brakelight switch wiring connector from switch. Remove hairpin and outer nylon washer from pedal pin. Slide brakelight switch off brake pedal pin just far enough for outer arm to clear pin. Remove brakelight switch. Remove booster-to-dash pedal nuts and cowl top intrusion bolt.
6. On vehicles with speed control, remove control amplifier mounted on lower outboard booster stud and set aside. Slide booster push rod, bushing, and inner nylon washer off brake pedal pin.
7. On all models, move booster forward until booster studs clear firewall. Rotate front of booster inboard (toward engine), and remove booster by raising until clear.

Installation (Mustang 2.3L)

To install, reverse removal procedure. Check for proper brake operation.