wheel FORD MUSTANG 2003 Workshop Manual

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
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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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4.
CAUTION: Use care not to damage the bleeder screw or front brake disc shield.
Install the disc brake caliper. 1. Hold the guide pins stationary.
2. Install the caliper bolts.
5. Install the wheel and tire assembly. For additional information, refer to Section 204 - 04 .
6. Lower the vehicle.
7. Fill the brake master cylinder reservoir with clean High Performance DOT 3 Brake Fluid C6AZ- 19542- AB or equivalent DOT 3 fluid meeting Ford specification ESA- M6C25-A. Install brake
master cylinder filler cap.
8. Inspect brake operation. Klj . 6 ba
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REMOVAL AND INSTALLATION
Brake Pads —
Cobra
Removal 1. Remove brake fluid in the master cylinder reservoir until the reservoir is half full.
2. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
3. Remove the tire and wheel 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 new pads in complete axle sets.
Inspect the pads for wear and contamination.
5. Remove the caliper locating pin E- clip.
6. Remove the caliper locating pin.
SECTION 206-
03: Front Disc Brake 2003 Mustang Workshop Manual Klj . 1 ba
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REMOVAL AND INSTALLATION
Caliper
Removal
1. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. Remove the wheel and tire assembly. For additional information, refer to Section 204 - 04 .
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.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is
spilled onto a painted or plastic surface, wash it with water immediately.
Disconnect the front brake hose (2078). 1. Remove the front brake flow bolt.
2. Disconnect the front brake hose.
3. Remove and discard the copper washers. Plug the front brake hose.
4. Remove the caliper bolts. 1. Hold the guide pins stationary.
2. Remove the caliper bolts.
SECTION 206-
03: Front Disc Brake 2003 Mustang Workshop Manual Klj . 1 ba
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4. Bleed the caliper. For additional information, refer to
Section 206 - 00 .
5. Install the wheel and tire assembly. For additional information, refer to Section 204 - 04 .
6. Fill the brake master cylinder reservoir (2K478) with clean High Performance DOT 3 Brake Fluid C6AZ- 19542- AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25- A. Install
brake master cylinder filler cap (2162).
7. Check the brake system operation. Klj . 4 ba
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REMOVAL AND INSTALLATION
Brake Caliper —
Cobra
Removal 1. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
2. Remove the tire and wheel assembly. For additional information, refer to Section 204 - 04 .
3. Remove the caliper locating pin E- clip.
4. Remove the caliper locating pin.
5. Remove the front brake flow bolt. 6. Remove the caliper. SECTION 206-
03: Front Disc Brake 2003 Mustang Workshop Manual Klj . 1 ba
32003 Mustang Workshop Manual
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SPECIFICATIONS
SECTION 206-
04: Rear Disc Brake 2003 Mustang Workshop Manual General Specifications
Item Specification
Disc brake lining wear limit 1.0 mm (0.040 in)
Disc thickness 15 mm (0.59 in)
Disc lateral runout 0.102 mm (0.004 in)
Disc thickness variation 0.01 mm (0.0004 in)
Hub runout —
Torque Specifications Description Nm lb-
ft lb-
in Rear wheel brake hose-
to-rear disc brake caliper retaining bolt 40 30 —
Rear disc brake support bracket bolts 103 76 —
Brake disc shield bolts 9-
12 — 80-
106 Rear brake pin retainer 33 25 — Klj . 1 ba
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DESCRIPTION AND OPERATION
Rear Disc Brake
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.
The rear disc brake system consists of:
zsolid, full- cast brake disc (2C026).
z hydraulically activated rear disc brake caliper (2552).
z integral mechanically (cable) operated parking brake mechanism that is self- adjusting.
Rear Disc Brake System Components SECTION 206-
04: Rear Disc Brake 2003 Mustang Workshop Manual Item Part Number Description
1 2552 Rear disc brake caliper
2 2C028 Brake disc shield
3 N606675-
S2 Bolt (3 req'd each side)
4 1104 Wheel hub
5 2C026 Brake disc
6 4B423 Rear wheel hub retainer
7 W623485-S2 Nut (2 req'd each side)
8 N805163-S100 Bolt (4 req'd) Klj . 1 ba
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