No brakes replaced EVERYTHING in the brake system, pads,rotors,calipers,brake lines,wheel cylinders and master cylinder. worked alright for a while, brake light would come on and go back off. came to a stop light, hit the brakes and the petal went to the floor. I thought I busted a brake line but that is not the case. it is full of brake fluid. emergency brake does not work either. it is like they are unhooked. I am stumped.....

Air in the system is what usually causes a caliper to lock up when everything else is functioning properly. If you can't get the air out of the system you will continue to have issues because when the brake system starts getting hot, the air expands inside the brake system causing the weakest brake to be applied. You will need to bleed the brakes once you fix the caliper that is not able to be bled. Remember, bleed the brakes from the farthest wheel from the master cylinder first and then continue to the nearest wheel last.

There are at least 2 items that will cause your problem. The first is when you changed the pads you place the caliper in a different place on the support pins that the caliper slides on to centralise the brakes on the rotor. These mounting pins are prone to rusting up and actually keeps one pad on the rotor as the caliper cannot centralise during brake application. The second is a problem that occurs when the brake fluid is pushed back into the master cylinder reservoir from pushing the piston back into the caliper. Muck in the lines is pushed back into the compensating ports in the Master cylinder causing the brakes to drag and build up pressure from the heat generated by having the brakes on. Try flushing out the brake system using metholated spirits or replace the master cylinder

adjust the rear brakes up properly

Section 06-03: Brakes, Front Disc 1999 Taurus, Sable Workshop Manual REMOVAL AND INSTALLATION Brake Shoe and Lining Removal

1. Remove brake master cylinder filler cap (2162). Check fluid level in brake master cylinder reservoir (2K478) . Remove brake fluid until brake master cylinder reservoir is half full. Discard removed fluid.
   

1. Raise vehicle on hoist.
   

1. Remove wheel and tire assembly from front disc brake rotor mounting face. Use care to avoid damage or interference with disc brake caliper (2B120) , front disc brake rotor shield (2K004) or front wheel knuckle (3K185) .
   

1. Remove rear brake pin retainers (2N386).
   

1. NOTE: It is not necessary to disconnect hydraulic connections.
   
   Lift disc brake caliper from front disc brake caliper anchor plate (2B292) and front disc brake rotor (1125) . Do not pry directly against metal caliper piston or damage will occur.
   

1. NOTE: To prevent damage, do not allow disc brake caliper to hang by the front brake hose (2078) .
   
   Position disc brake caliper out of the way.
   

1. Remove inner outer brake shoe and lining (2001) assembly from front disc brake caliper anchor plate .
   

1. Inspect both rotor braking surfaces. Minor scoring or buildup of lining material does not require machining or replacement of front disc brake rotor.
   

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remove the 2 pins, #10 in pic. Usually has a dust cover over pin accessopening. Usually torx haed or hex head bolts (pins).

No, see procedure below listed at autozone.com. Try opening bleeder. You may have a kink somewhere or hose decomposing internally. Else the piston is locked in place. Was the brake working before replacing pads?

1. Remove 1 / 2 of the volume of brake fluid from the master cylinder to prevent overflow when the caliper piston is compressed.
2. Raise and safely support the vehicle.
3. Remove the wheel and tire assemblies.
4. Remove the brake caliper without disconnecting the brake line. Support the caliper with a length of wire. Do not let the caliper hang from the brake hose.
   NOTE On some disc brake systems it is not necessary to remove the caliper when installing new brake pads. Remove the lower slide bolt and rotate the caliper upward to remove the pads.
   
5. Remove the brake pads and shims. Inspect the brake rotor and machine or replace as necessary. Check the minimum thickness (specification is cast into the rotor) before machining.

To install:

1. Use a suitable tool to push the caliper piston into its bore.
2. Apply a thin coat of grease to the rear face of the brake pad and install the shim. Install the brake pads.
3. Install the calipers. Lubricate the caliper bolts and boots. If equipped with a 4-cylinder engine, tighten the caliper mounting bolts to 24 ft. lbs. (33 Nm). If equipped with a 6-cylinder engine, tighten the caliper mounting bolts to 54 ft. lbs. (74 Nm).
4. Install the wheel and tire assemblies and lower the vehicle.
5. Apply the brakes several times to seat the pads before moving the vehicle. Check the fluid in the master cylinder and add as necessary.

Removal & Installation Front To Remove:

1. Inspect the fluid level in the master cylinder reservoir. Remove fluid from the reservoir until the level is lower then half way between the MAX and MIN levels.
2. Remove the tire and wheel assembly.
3. Install 2 wheel nuts to secure the rotor on the hub.
4. Remove the bottom brake caliper pin bolt.
5. Pivot the brake caliper body upward and secure out of the way. Do NOT disconnect the hydraulic brake flexible hose from the caliper.
6. Compress the piston back into the bore using a C-clamp. Figure of brake assembly with caliper raised showing brake pads in mounting bracket
   
   
7. Remove the inboard and outboard brake pads from the brake caliper bracket.

To Install:

1. Install the brake pad retainers and both brake pads into the caliper bracket.
2. Pivot the brake caliper down over the brake pads and into the brake caliper bracket. Insert the lower brake caliper pin bolt and torque bolt to 70 ft-lb. (95 Nm).
3. Reinstall the tire and wheel assembly.
4. Lower the vehicle.
5. Refill the master cylinder. Pump the brake pedal several times to seat the pads against the rotor.
6. Check the master cylinder level and add fluid as necessary.

Rear To Remove:
Rear disc pads R&I

1. Inspect the fluid level in the master cylinder reservoir. Remove fluid from the reservoir until the level is lower then half way between the MAX and MIN levels.
2. Remove the tire and wheel assembly.
3. Install 2 wheel nuts to secure the rotor on the hub.
4. Remove the upper caliper mounting bolt.
5. Pivot the caliper down to access the pads.
6. Remove the inboard and outboard pads from the caliper bracket.
7. Remove the brake pad clips from the caliper bracket.
8. Compress the piston back into the bore using a C-clamp and the old inner pad.

To Install:

1. Install new brake clips in the caliper bracket.
2. Install the inboard and outboard pads in the caliper bracket.
3. Pivot the caliper up over the pads.
4. Reinstall the upper mounting bolt and tighten to 32 ft. lbs. (44 Nm).
5. Remove the 2 wheel nuts securing the rotor.
6. Reinstall the tire and wheel assembly.
7. Refill the master cylinder. Pump the brake pedal several times to seat the pads against the rotor.
8. Check the master cylinder level and add fluid as necessary.

YOU NEED REMOVE A LITTLE BRAKE FLUID FROM MASTER CYLINDER.THEN YOU RAISE VECHICLE SAFELY.SUPPORT IT WITH JACK STAND.MAKE SURE VECHICLE IS ON LEVEL SOLID GROUND.REMOVE TIRE OR WHEEL.THEN YOU NEED A LARGE C - CLAMP.PLACE C - CLAMP OVER BRAKE CALIPER AND BRAKE SHOE BACKING.TIGHTEN C - CLAMP JUST ENOUGH PUSH CALIPER PISTON BACK IN CYLINDER BORE TO REMOVE CALIPERS FROM ROTORS.TO REMOVE BRAKE CALIPER YOU NEED 2 OPEN AND BOX END WRENCHES ONE TO HOLD CALIPER SLIDE PINS AND THE OTHER WRENCH FOR LOOSEN CALIPER BOLTS.THEN YOU REMOVE CALIPER AND REPLACE FRONT BRAKE SHOES.IF YOU NEED TO REMOVE BRAKE ROTORS JUST REMOVE THE BRAKE CALIPER CARRIER SUPPORT BOLTS THE REMOVE THE BRAKE CALIPER CARRIER SUPPORT THEN REMOVE ROTOR.YOU NEED TO REPLACE BOLTS WITH NEWS AND USE LOCK TIGHT.THEN YOU PUT IN NEW BRAKE PADS IN CALIPER PUT CALIPER BACK ON SUPPORT CARRIER.REPLACE WITH NEW BOLTS USE LOCK TIGHT THEN TORQUE BOLTS TO 26 FT LBS.MAKE SURE MASTER CYLINDER COVER IN PLACE.WHEN YOU FINISH REPLACING BOTH FRONT BRAKE PADS PUMP BRAKE PEDAL TO SEAT BRAKE SHOES AGAINST BRAKE ROTORS SO YOU WILL HAVE FIRM BRAKES WHEN YOU APPLY THEM. THEN CHECK YOUR BRAKE FLUID LEVEL IN MASTER CYLINDER MAKE SURE ITS NOT LOW. MAKE SURE YOU HAVE FIRM BRAKES BEFORE DRIVING.IF YOU HAVE ANY PROBLEMS CHANGING FRONT BRAKE PADS YOU CAN GO TO ANY AUTO PARTS STORE AND BUY A HAYNES REPAIR MANUAL.

no they are inverted flare fittings no seals check all lines and calipers/wheel cylinders if all are dry remove the vacuum hose from the booster if there is brake fluid in the hose the master cylinder is bad

You may have a leak in the booster or master cylinder. You can put a pressure tester on the system to test for leaks. It does sound like you have an air leak.
You can try to bleed the master cylinder, then slave cylinder, then brake lines.

I have had exacly the same issue, the mechanic replaced the brake pads, calipers, hoses/brake lines, then after all that and it still happening, he replaced the brake master cylinder and all was well, except for my wallet !!!!