Ford Crown Victoria, Mercury Grand Marquis, Marauder, Lincoln Town Car 1999-2005

Brake Disc (Rotor)



Check the disc brake rotor for scoring, cracks or other damage. Check the minimum thickness and rotor runout.

Either foreign material build-up or contamination on the rotor braking surface or uneven rotor thickness causes a brake pulsation that is present during brake application. If there is a foreign material build-up or contamination found on the rotor or lining surfaces, hand sand the linings and rotors. Uneven rotor thickness (thickness variation) may be caused by excessive runout, caliper drag or the abrasive action of the brake lining. If brake pulsation is present, attempt stopping the vehicle with the transmission in the NEUTRAL position. If the pulsation is gone, the drivetrain should be inspected. If the pulsation remains, inspect the brakes.

Check the rotor thickness using a micrometer or calipers. The brake rotor minimum thickness must not be less than 0.972 in. on 1988-91 vehicles or 0.974 in. on 1992-99 vehicles.

Rotor runout can be checked using a dial indicator. Mount the indicator to the spindle or upper control arm and position the indicator foot on the center of the braking surface. Rotate the rotor to check the runout. On 1992-99 vehicles, make sure there is no rust or foreign material between the rotor and hub face. Hold the rotor to the hub by inverting the lugnuts and tightening them to 85-105 ft. lbs. (115-142 Nm). Rotor runout must not exceed 0.003 in.

If rotor runout exceeds specification on 1988-91 vehicles, machine the rotor if it will not be below the minimum thickness specification after machining. On 1992-00 vehicles, the rotor can be repositioned on the hub to obtain the lowest possible runout. If runout remains excessive, remove the rotor and check the hub runout. Replace the hub if hub runout exceeds 0.002 in. If after replacing the hub, rotor runout remains excessive, machine the rotor if it will not be below the minimum thickness specification after machining.

Removal & Installation

Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers.

If the vehicle is equipped with air suspension, 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 luggage compartment. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations. Failure to follow these instructions may result in personal injury.

Click image to see an enlarged view

Fig. Exploded view of the front disc brake assembly

Do not allow the disc brake caliper to hang from the brake hose. Damage to the hose can result.

  1. Before servicing the vehicle, refer to the Precautions section.
  3. Remove the wheel and tire assembly.
  5. Remove the anchor plate as follows:
    Use the correct type and length bolts when reinstalling.

    Remove the bolts and position the brake caliper aside.
    Remove the brake pads and stainless steel slippers from the anchor plate.
    Remove the guide pins and guide pin boots and check the guide pins for binding and damage.
    Install new guide pins if worn or damaged.
    Remove the bolts and the caliper anchor plate and discard the bolts.

  7. Match-mark the brake disc with a wheel stud.
    If the brake disc cannot be removed easily, apply rust penetrant on brake disc to wheel hub mating surfaces.

  9. Remove the retention ring and the brake disc and discard the retention ring.

    Click image to see an enlarged view

    Fig. Anchor plate mounting


To install:

  1. Clean any rust or foreign material from the brake disc, wheel and wheel hub.
  3. Use brake parts cleaner to clean the brake disc and hub surfaces.
  5. Apply anti-seize lubricant to the hub mounting surface to prevent future corrosion.
  7. Install the rotor over the wheel studs with a new retention ring.
  9. Install the anchor plate with new bolts and torque to 118 ft. lbs. (160 Nm)