Mercury Cougar 2000-2002

Brake Pads

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove or disconnect the following:

    1 / 2 of the brake fluid from the master cylinder reservoir
     
    Wheels
     
    Cotter pin and guide pin

    Click image to see an enlarged view

    Fig. Rear disc brake components-Cougar

     
    Caliper locating pin cover and remove the locating pin
     

  4.  
  5. Swing the rear disc brake caliper away from the brake rotor and anchor plate. There is no need to remove the parking brake cable or brake hose.

    Inner and outer disc brake pads
     

  6.  

To install:

  1. If installing new disc brake pads, use rear caliper piston adjuster T87P-2588-A or similar tool, to rotate the rear disc brake piston clockwise, retracting the caliper piston. This will allow room for the new brake pads.

    Click image to see an enlarged view

    Fig. Diagram of rear caliper piston and the adjuster tool-Cougar

  2.  
  3. Install the inner and outer disc brake pads.
  4.  
  5. Swing the rear disc brake caliper back into position over the disc brake pads.
  6.  
  7. Clean the locating pin threads and apply 1 drop of a thread locking agent or similar sealer.
  8.  
  9. Apply a small amount of disc brake caliper slide grease to the shaft of the locating pin.
  10.  
  11. Install or connect the following:

    Locating pin and torque to 30 ft. lbs. (41 Nm)
     
    Guide pin and the cotter pin
     

  12.  
  13. Adjust the parking brake by operating the parking brake control several times.

    Wheel and tire assembly. Torque the lug nuts to 62 ft. lbs. (85 Nm).
     

  14.  
  15. Adjust the parking brake by operating the parking brake control several times.
  16.  
  17. Pump the brake pedal several times to achieve a good pedal before attempting to move the vehicle.
  18.  
  19. Check the brake fluid level in the master cylinder fluid reservoir and add fluid as necessary.
  20.  
  21. Road test the vehicle and check for proper brake system operation.
  22.  

  1. Remove 1 / 2 of the brake fluid from the master cylinder reservoir.
  2.  
  3. Remove the wheels.
  4.  
  5. Remove the cotter pin and guide pin.

    Click image to see an enlarged view

    Fig. Rear disc brake components-Contour, Mystique

  6.  
  7. Remove the caliper locating pin cover and remove the locating pin.
  8.  
  9. Swing the rear disc brake caliper away from the brake rotor and anchor plate. There is no need to remove the parking brake cable or brake hose.
  10.  
  11. Remove the inner and outer disc brake pads.
  12.  

To install:

  1. If installing new disc brake pads, use rear caliper piston adjuster T87P-2588-A or similar tool, to rotate the rear disc brake piston clockwise, retracting the caliper piston. This will allow room for the new brake pads.

    Click image to see an enlarged view

    Fig. Diagram of rear caliper piston and the adjuster tool-Contour, Mystique

  2.  
  3. Install the inner and outer disc brake pads.
  4.  
  5. Swing the rear disc brake caliper back into position over the disc brake pads.
  6.  
  7. Clean the locating pin threads and apply 1 drop of a thread locking agent or similar sealer.
  8.  
  9. Apply a small amount of disc brake caliper slide grease to the shaft of the locating pin.
  10.  
  11. Reinstall the locating pin and torque to 30 ft. lbs. (41 Nm).
  12.  
  13. Reinstall the guide pin and the cotter pin.
  14.  
  15. Adjust the parking brake by operating the parking brake control several times.
  16.  
  17. Reinstall the wheel and tire assembly. Torque the lug nuts to 62 ft. lbs. (85 Nm).
  18.  
  19. Adjust the parking brake by operating the parking brake control several times.
  20.  
  21. Pump the brake pedal several times to achieve a good pedal before attempting to move the vehicle.
  22.  
  23. Check the brake fluid level in the master cylinder fluid reservoir and add fluid as necessary.
  24.  
  25. Road test the vehicle and check for proper brake system operation.
  26.  

 
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