Brake Disc (Rotor) Ford Taurus/Sable 1996-1999 Repair Guide

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REMOVAL & INSTALLATION

Front

See Figures 1, 2 and 3

Fig. 1: Remove the caliper bracket retaining bolts and...

Fig. 2: ... remove the bracket from the vehicle

Fig. 3: Carefully remove the rotor from the hub assembly

1. Raise and safely support the vehicle.

2. Remove the wheel and tire assembly.

3. Remove the disc brake caliper and the caliper anchor bracket as an assembly. Discard the bracket retaining bolts. Position the caliper aside and support it with a length of wire. Do not allow the caliper to hang by the brake hose.

To prevent contamination of the disc brake caliper guide pin journals, do not separate the disc brake caliper from the caliper anchor bracket.

4. Separate the disc brake rotor from the hub assembly by pulling it off the hub studs. If additional force is required to remove the rotor, apply rust penetrate on the front and rear rotor/hub mating surfaces and then strike the rotor between the studs with a plastic hammer. If this does not work, attach a suitable 3-jaw puller and remove the rotor.

If excessive force must be used to remove the rotor, it should be checked for lateral run-out before installation.

5. Check the rotor for scoring and/or other wear. Machine or replace, as necessary.

To install:

6. If the disc brake rotor is being replaced, remove the protective coating from the new rotor. If the original rotor is being installed, make sure the rotor braking surfaces are clean.

7. Apply a small amount of silicone dielectric compound or equivalent, to the pilot diameter of the disc brake rotor. Install the rotor on the hub assembly.

8. Install remaining components in the reverse order of removal. Torque the following

   • Caliper anchor bracket bolts to 65-87 ft. lbs. (88-118 Nm)

   • Lug nuts to 85-105 ft. lbs. (115-142 Nm)

9. Pump the brake pedal several times prior to moving the vehicle to seat the disc brake pads to the rotor.

10. Road test the vehicle and check the brake system for proper operation.

Rear

See Figures 4 through 8

Fig. 4: Remove the caliper bracket retaining bolts and...

Fig. 5: ... remove the bracket from the vehicle

Fig. 6: If equipped, pry or cut off the...

Fig. 7: ... retainer nuts placed on the rotors from the assembly line

Fig. 8: Carefully remove the rotor from the hub assembly

1. Raise and safely support the vehicle.

2. Remove the wheel and tire assembly.

3. Remove the caliper assembly from the disc brake rotor and support it with a length of wire. Do not let the caliper hang from the brake line.

4. Remove the upper and lower support bracket retaining bolts. Remove the support bracket.

5. Remove 2 retainer nuts and remove the disc brake rotor from the hub. Check the rotor for scoring and/or other wear. Machine or replace, as necessary.

To install:

6. If the disc brake rotor is being replaced, remove the protective coating from the new rotor. If the original rotor is being installed, make sure the rotor braking surfaces are clean.

7. Install the disc brake rotor on the hub assembly.

Lubricate the hub pilot with a suitable caliper slide grease to ease future rotor removal.

8. Install 2 retainer nuts to hold the disc brake rotor in position.

9. Install the disc brake caliper support bracket and tighten the support bracket retaining bolts to 65-87 ft. lbs. (88-118 Nm).

10. Install the brake pads and disc brake caliper assembly.

11. Install the wheel and tire assembly. Install the lug nuts and torque to 85-105 ft. lbs. (115-142 Nm).

12. Pump the brake pedal several times prior to moving the vehicle to seat the brake pads to the rotor.

13. Road test the vehicle and check the brake system for proper operation.

INSPECTION

See Figures 9 and 10

Fig. 9: Check brake rotor thickness in several places around the rotor

Fig. 10: Mount the dial indicator and zero the indicator

Rotor thickness should be measured any time a brake inspection is done. Rotor thickness can be measured using a brake rotor micrometer or Vernier caliper. Measure the rotor thickness in several places around the rotor. Compare the thickness to the specifications chart found at the end of this section.

The run-out of the brake rotor should be checked any time a vibration during braking occurs. Excessive run-out can be caused by a build-up of rust scale or other particles on the rotor or hub surfaces. Remove the rotor and thoroughly clean the hub and rotor-to-hub mounting surface on the back of the rotor. Mount a dial indicator to a suspension member and zero the indicator stylus on the face of the rotor. Rotate the rotor 360 degrees by hand and record the run-out.

Compare measurements to the brake specifications chart. If the thickness and run-out do not meet specifications, replace the rotor.