FORD MUSTANG 2003 Workshop Manual

13. If the brake disc TIR is still out of specification, measure and record the thickness of the brake
disc. If thickness is sufficient to machine the brake disc to the runout specification, go to Step
14. If the thickness is not sufficient, install a new brake disc and recheck the TIR.
14. NOTE: Brake disc machining must be done with an on- vehicle lathe. Follow the lathe
manufacturer's instructions.
Machine the brake disc if final thickness will not be less than the maximum specification.
Recheck the brake disc runout. Klj . 3 ba
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SPECIFICATIONS
SECTION 206-
03: Front Disc Brake 2003 Mustang Workshop Manual General Specifications
Item Specification
Disc brake lining wear limit 1.0 mm (0.040 in)
Disc thickness (Mustang/Mustang Cobra) 26 mm (1.02 in)/28 mm (1.10 in)
Disc lateral runout 0.05 mm (0.002 in)
Disc thickness variation 0.009 mm (0.00035 in)
Hub runout 0.025 mm (0.001 in)
Torque Specifications Description Nm lb-
ft Disc brake caliper bolt 31 23
Front brake hose bolt 40 30
Front disc brake caliper anchor plate bolt 115 85
Disc brake caliper bleeder screw 10 7 Klj . 1 ba
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DESCRIPTION AND OPERATION
Front Disc Brake
Front Disc Brake Components
Disc Brake Caliper Components SECTION 206-
03: Front Disc Brake 2003 Mustang Workshop Manual Item Part Number Description
1 — Bleeder screw and bleeder screw cap assy
2 2N386 Caliper bolt
3 2B296 Guide pin
4 2A492 Guide pin boot
5 2B120 Disc brake caliper
6 2B164 Anti-
rattle spring 7 2B292 Front disc brake caliper anchor plate
8 385116-S2 Flow bolt
9 2078 Front brake hose Klj . 1 ba
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The front disc brake caliper (2B120):
zbolts to the front disc brake caliper anchor plate (2B292), which bolts to the front wheel spindle
(3105).
z is a pin slider, dual piston design.
The front brake discs (1125):
zare of a ventilated full- cast design, with non-directional cooling fins.
z are serviced with the disc brake caliper and front disc brake caliper anchor plate removed.
The front brake disc shield (2K005): Item Part Number Description
1 2B120 Disc brake caliper
2 2L126 Bleeder screw cap
3 2208 Bleeder screw
4 2B164 Anti-
rattle spring 5 2196 Caliper piston
6 2B115 Piston seal
7 2207 Piston dust boot
8 2L200 Pad slipper
9 2B292 Front disc brake caliper anchor plate
10 2001 Brake pads
11 2A492 Guide pin boot
12 2B296 Guide pin
13 2N386 Caliper bolt Klj . 2 ba
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z
is riveted to the front wheel spindle.
z protects the front wheel bearings and inboard surface of the front brake disc.
The pads:
zare housed in the front disc brake caliper anchor plate.
z are of a non- asbestos, non- metallic composition. Klj . 3 ba
32003 Mustang Workshop Manual
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REMOVAL AND INSTALLATION
Pads
Removal
1. Remove brake master cylinder filler cap (2162). Check brake fluid level in brake master cylinder reservoir (2K478). Remove fluid until brake master cylinder reservoir is half full.
2. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
3. Remove the wheel and tire assembly. For additional information, refer to Section 204 - 04 .
4. CAUTION: Install new pads if worn to or past the specified thickness above the
metal backing plate or rivets. Install pads in complete axle sets.
Inspect the pads for wear and contamination.
5. Remove the caliper bolts. 1. Hold the guide pins stationary.
2. Remove and discard the caliper bolts.
SECTION 206-
03: Front Disc Brake 2003 Mustang Workshop Manual Klj . 1 ba
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6.
CAUTION: Do not pry in caliper sight hole to retract pistons as this can damage the
pistons and boots.
CAUTION: When removing the disc brake caliper (2B120), never allow it to hang
from the brake hose. Provide a suitable support.
Lift the caliper off the anchor plate (2B292).
7. Remove the pads and the pad slippers. 1. Remove the pads and verify thickness.
2. Remove and discard slippers. Klj . 2 ba
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8. Measure the front brake disc thickness.
zInstall a new front brake disc (1125) if not within specification.
9. Inspect the disc brake caliper. zIf leaks or damaged boots are found, disassembly is required. For additional information,
refer to Caliper in this section. Klj . 3 ba
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10. Inspect the front disc brake anchor plate assembly.
zCheck the guide pin boots for damage.
z Check the guide pins for binding and damage.
z Worn or damaged pins should be installed new.
Installation 1. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the
pad lining material. Do not install contaminated pads.
NOTE: Install all hardware supplied with pad kits.
Install the pads. 1. Install the new pad slippers.
2. Install the pads. Klj . 4 ba
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2.
NOTE: Use a wood block or used pad to protect pistons and boots.
Compress the caliper pistons (2196).
3. Make sure the anti- rattle spring is correctly positioned in the caliper. Klj . 5 ba
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