Front disc brake assembly diagram - 1999 Mercury Tracer

Buy a manual and read it. The manual will have diagrams and tell you the proceedure for repairing the braking system.

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).

Brake Pads
Removal & Installation
Front





3.4L front disc brake assembly









4.0L and 4.7L front disc brake assembly




To Remove:

1. Before servicing the vehicle, refer to the precautions in the beginning of
   this section.
   
2. Remove or disconnect the following:
   
   
   
   • Front wheel
     
   • Clip, 2 caliper pins, the anti-rattle spring then remove the 2 brake pads
     and the 4 anti-squeal shims

To Install:

CAUTION
Only replace brake pads on 1 side of the
vehicle at a time. Failure to use this procedure could cause the caliper pistons
on the opposite side of the vehicle to pop out requiring the reconditioning or
replacement of the brake caliper.

1. Remove a small amount of brake fluid from the master cylinder.
   
2. Install a used brake pad into the caliper and compress the caliper pistons.
   
3. Apply disc brake grease to both sides of the inner anti-squeal shims.
   
4. Install or connect the following:
   
   
   
   • Anti-squeal shims to the new brake pads
     NOTE: When replacing worn pads, the anti-squeal shims must be replaced
     together with the pads.
     
     
   • 2 brake pads
     
   • Anti-rattle spring and the 2 caliper pins
     
   • Clip
     
   • Front wheel
   
   
5. Depress the brake pedal several times to seat the brake pads.
   
6. Check the brake fluid level and top off as needed.

Rear
To Remove:

1. Before servicing the vehicle, refer to the precautions in the beginning of
   this section.
   
2. Remove or disconnect the following:
   
   
   
   • Rear wheel
     
     
     
     
     
     
     
     
     
     
     
   • 2 cylinder slide pins from rear caliper assembly
     
   • Caliper assembly from rear caliper mounting
     
   • 2 brake pads with anti-squeal shims from rear caliper mounting
     
   • 2 anti-squeal shims from each disc brake pads
     
   • Pad wear indicator plate from the inner side disc brake pad
     
   • 4 pad support plates from the rear caliper mounting

To Install:

1. Install or connect the following:
   
   
   
   • 4 pad support plates on the rear caliper mounting
     
   • Pad wear indicator plate on the inside brake pad
     Note: Install the pad wear indicator facing downward.
     
     
   • Anti-squeal shims on each brake pad
     
   • 2 disc brake pads with anti-squeal shims to the caliper assembly
   
   
2. Apply lithium soap base glycol grease to the sliding part of 2 caliper slide
   pins.
   
3. Install or connect the following:
   
   
   
   • Disc brake caliper assembly with 2 caliper slide pins
     
   • Torque to 65 ft-lbs (88 Nm)
     
   • Rear wheel
   
   
4. Depress the brake pedal several times to seat the brake pads.
   
5. Check the brake fluid level and top off as needed.

--- Removal & Installation
Front
To Remove:

1. Before servicing the vehicle, refer to the precautions in the beginning of
   this section.
   
2. Remove or disconnect the following:
   
   
   
   • Front wheel
     
   • Front brake caliper assembly
   
   
3. Make matchmarks on the disc and the axle hub.
   
4. Remove the front disc.

To Install:

1. Align matchmarks and disc onto axle hub.
   
2. Install or connect the following:
   
   
   
   • Front brake caliper assembly with the 2 bolts
     
     
     
     1. Torque to 90 ft-lbs (123 Nm)
     
     
   • Front wheel

PATH: Brakes > Front Disc Brakes > Brake Disc (Rotor) > Removal & Installation Removal & Installation

1. Raise and support the front of the vehicle on jackstands. Remove the front wheels.
   
2. Remove the caliper assembly; do not let the caliper assembly hang by the brake hose, instead support it with a piece of wire looped around the front spring or control arm.
   
3. Remove the retaining screw from the brake rotor and remove the rotor from the hub.
   

An impact driver, No. 3 phillips screwdriver bit, and a hammer may be needed to remove the retaining screw. It is fairly easy to destroy the screw slots using an ordinary phillips screwdriver to remove the tightly driven screw (see photo).

1. To install the disc, replace the disc on the hub, screw in the retaining screw and replace the caliper assembly.
   

PATH: Brakes > Rear Disc Brakes > Brake Disc (Rotor) > Removal & Installation Removal & Installation

1. Raise and safely support the vehicle.
   
2. Remove the wheel and tire assembly.
   
3. Disconnect the caliper from the caliper bracket. Support the caliper out of the way with a length of wire. Do not allow the caliper to hang from the brake hose.
   
4. Remove the caliper bracket.
   
5. Remove the two 6mm screws and the brake disc. If the brake disc is difficult to remove, install two 8mm bolts into the threaded holes and tighten them evenly to prevent cocking the rotor.
   
6. Install the rotor in position. Install the two 6mm retaining screws.
   
7. Install the brake caliper. Install the tire and wheel assembly.
   

PATH: Brakes > Rear Disc Brakes > Brake Disc (Rotor) > Removal & Installation Removal & Installation

1. Raise and safely support the vehicle.
   
2. Remove the wheel and tire assembly.
   
3. Disconnect the caliper from the caliper bracket. Support the caliper out of the way with a length of wire. Do not allow the caliper to hang from the brake hose.
   
4. Remove the caliper bracket.
   
5. Remove the two 6mm screws and the brake disc. If the brake disc is difficult to remove, install two 8mm bolts into the threaded holes and tighten them evenly to prevent cocking the rotor.
   
6. Install the rotor in position. Install the two 6mm retaining screws.
   
7. Install the brake caliper. Install the tire and wheel assembly.
   
8. 
   

best advice is if brakes work then its got into box by mistake,unless its a small coil spring for the brake pad wear sensors

Caliper Removal

1. CAUTION: Do not use heat to loosen a seized lug nut . Heat can damage the wheel and the wheel bearings.
   Loosen the lug nuts.
   1. Remove the center cap.
1. With the weight of the vehicle on the wheels, loosen the lug nuts.
1. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS.
   Raise and support the vehicle.
1. Remove the wheel and tire assembly.
   1. Remove the lug nuts.
   1. Remove the wheel and tire assembly.
2. CAUTION: Replace the lining if worn to or past specifications. Replace the brake shoes and linings in complete axle sets. Inspect the brake shoes and linings for wear or contamination.
3. WARNING: BRAKE 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.
   Disconnect the front brake hose (2078).
   1. Remove the front brake hose bolt.
   1. Remove the copper washers. Plug the front brake hose.
1. Disconnect the front brake hose
4. Remove the disc brake caliper (2B120).
   1. Remove the two caliper bolts.
   1. Lift the front disc brake caliper (2B121) off the front disc brake caliper anchor plate.
5. On 4x2 vehicles, measure the front disc brake hub and rotor (1102) thickness.
   • Replace the front disc brake hub and rotor if not within specifications 27.7mm Min.
6. On 4x4 vehicles, measure the front disc brake rotor thickness.
   • Replace thhe front disc brake rotor if not within specifications. 27.7mm Min.
7. Inspect the disc brake caliper for leaks.
   • If leaks are found, disassembly is required

1999 Taurus/Sable Section 06-03: Brakes, Front Disc 1999 Taurus/Sable Workshop Manual REMOVAL AND INSTALLATION Procedure revision date: 06/25/1998 Disc Removal

1. Raise vehicle on hoist.
   

1. Remove wheel and tire assembly. Be careful to avoid damage or interference with caliper bleeder screw fitting and front disc brake rotor shield (2K004).
   

1. CAUTION: Handle front disc brake rotor (1125) and disc brake caliper (2B120) assembly in such a way as to prevent deformation of front disc brake rotor , and nicking, scratching or contamination of brake linings/rotor surfaces.
   NOTE: To prevent damage, do not allow disc brake caliper to hang by the front brake hose (2078) .
   
   
   Remove caliper anchor plate bolts and discard. Position disc brake caliper out of the way. Prevent separation of caliper housing from anchor bracket because contamination of guide pin journals can occur.
   

1. NOTE: If excessive force must be used during front disc brake rotor removal, the front disc brake rotor should be checked for runout prior to installation.
   
   
   If additional force is required to remove front disc brake rotor , apply Rust Penetrant and Inhibitor F2AZ-19A501-A or equivalent meeting Ford specification ESR-M99C56-A on front and rear rotor/hub mating surfaces. First, strike front disc brake rotor between lug bolts (1107) with a plastic hammer. If this does not work, attach 2-3 Jaw Puller 205-D027 (D80L-1013-A) or equivalent and remove front disc brake rotor . Remove front disc brake rotor from wheel hub (1104) assembly by pulling it off the lug bolts.
   

Installation

1. If original front disc brake rotor is being installed, make sure rotor braking and mounting surfaces are clean.
   

1. CAUTION: Failure to clean rust and foreign material from rotor and hub mounting faces when installing new or old front disc brake rotors will result in high rotor runout, which will speed up the development of brake roughness shudder vibration.
   Apply a small amount of Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to pilot diameter of front disc brake rotor.
   

1. Install front disc brake rotor on wheel hub assembly.
   

1. Install disc brake caliper and new caliper anchor bracket bolts on front disc brake rotor . Tighten caliper anchor bracket bolts to 88-118 Nm (65-87 lb-ft).
   

1. CAUTION: Failure to tighten lug nuts (1012) in a star pattern may result in high rotor runout, which will speed up the development of brake roughness, shudder and vibration.
   Install wheel and tire assembly on vehicle. Tighten lug nuts to 115-142 Nm (85-104 lb-ft) using Rotunda Accutorq® Lug Nut Socket 164-R0303 or equivalent on a 1/2 inch air impact wrench, or use a torque wrench.
   

1. Lower vehicle.
   

1. Pump brake pedal prior to moving vehicle to position brake linings.
   

1. Road test vehicle.
   

here is procedure

Section 04-01: Suspension and Wheel Hubs, Front 1996 Taurus, Sable Workshop Manual
REMOVAL AND INSTALLATION Wheel Hub Bolt Removal

1. Raise vehicle on hoist.
   

1. Remove wheel and tire assembly. Refer to Section 04-04 .
   

1. Remove disc brake caliper (2B120), and front disc brake rotor (1125). Refer to Section 06-03 .
   

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. Refer to Section 00-02 .
   

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). ( I think it is a T 40 torx bit you need)
   

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. Position disc brake caliper out of the way and support with wire to avoid damaging the disc brake caliper and front brake hose (2078).
   

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

1. Remove inner brake shoe and lining assembly.
   

1. Position lug bolt (1107) to clear front wheel knuckle (3K185).
   

1. Remove lug bolt from wheel hub (1104).
   
   
   
   

Installation

1. Install lug bolt into wheel hub.
   

1. Using a lug nut (1012), seat wheel hub bolt into wheel hub.
   

1. Install front disc brake rotor and disc brake caliper. Refer to Section 06-03 .
   

1. Install wheel and tire assembly. Tighten lug nut to 115-142Nm (85-104 lb-ft).
   

The hard part is pressing the caliper piston abck into the caliper so you can get the new, thicker pads over the rotor. A large C Clamp works best.

SECTION 206-03: Front Disc Brake 2001 Villager Workshop Manual
REMOVAL AND INSTALLATION Pads —Front Disc Brake Removal

1. Remove the wheel and tire assembly. For additional information, refer to Section 204-04 .

1. Remove the front disc brake caliper bolts. torx bit. T20?

1. Support the front disc brake caliper from the front strut and spring assembly using mechanics wire.

1. Remove the front disc brake pads.
   1. Remove the outboard front disc brake pad.
   1. Remove the inboard front disc brake pad.

Installation

1. CAUTION: Make sure the master cylinder reservoir does not overfill and spill brake fluid while retracting the front disc brake caliper piston.
   NOTE: It is necessary to fully retract the front disc brake caliper piston in the bore before installing the front disc brake pads.
   Install the front disc brake pads.
   1. Install the inboard front disc brake pad.
   1. Install the outboard front disc brake pad.

Caution. The outer pads are left and right. put left on driver side.

1. Position the front disc brake caliper on the front-wheel knuckle and install the brake caliper pin bolts.

1. WARNING: It is necessary to depress the brake pedal several times to position the front disc brake caliper piston before driving the vehicle.