FORD MUSTANG 2003 Workshop Manual

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DISASSEMBLY AND ASSEMBLY
Caliper
Disassembly
1. Remove the disc brake caliper (2B120). For additional information, refer to Caliper in this
section.
2. Drain the remaining brake fluid from disc brake caliper.
3. Apply low air pressure to the fluid port in the disc brake caliper. 1. Place a block of wood between the caliper bridge and the caliper pistons (2196).
2. Apply low air pressure to the fluid port in the disc brake caliper and force out the caliper pistons to the block of wood.
4. Remove the caliper pistons. 1. Remove the block of wood.
2. Remove the caliper pistons.
5. Remove and discard the piston seals and boots.
SECTION 206-
03: Front Disc Brake 2003 Mustang Workshop Manual Klj . 1 ba
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6. Remove and discard the bleed screw and cap.
Assembly
1. CAUTION: Do not hone the caliper bores. Caliper pistons are not available for
honed caliper bores.
Clean and inspect the caliper pistons and the disc brake caliper.
zRemove dirt and debris.
z Examine the caliper pistons for surface irregularities, scoring or wear. Damaged caliper
pistons should be installed new.
z Clean the caliper bores with Metal Brake Parts Cleaner F3AZ-19579- SA or equivalent
meeting Ford specification.
z If the caliper bores are corroded or excessively scored, install a new disc brake caliper.
z Lubricate the caliper pistons and piston seals before assembly. Klj . 2 ba
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2.
CAUTION: Never reuse piston seals and dust boots.
NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been
allowed to stand in an open container for an extended period of time.
Lubricate the caliper piston, piston seal and caliper bores with clean High Performance DOT 3
Brake Fluid C6AZ-19542- AB or equivalent DOT 3 fluid meeting Ford specification ESA- M6C25-
A.
3. Install the caliper piston. Klj . 3 ba
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1. Install the piston seal.
2. Install the piston boot on the piston.
3.
CAUTION: Be careful not to damage or dislodge the piston seal.
Insert the caliper piston.
4. CAUTION: Be careful not to cock the caliper piston.
Press the caliper piston into the bore.
4. Install a new bleed screw and cap.
5. Install the disc brake caliper. For additional information, refer to Caliper in this section. Klj . 4 ba
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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
22003 Mustang Workshop Manual
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REMOVAL AND INSTALLATION
Caliper
Removal
1. Raise the vehicle on a hoist. For additional information, refer to Section 100 - 02 .
2. Remove the wheel and tire assembly. For additional information, refer to Section 204 - 04 .
3. Disengage the parking brake cable end from the parking brake lever arm.
4. Remove the parking brake cable retaining clip.
5. Remove the parking brake cable and conduit.
SECTION 206-
04: Rear Disc Brake 2003 Mustang Workshop Manual Special Tool(s)
Rear Caliper Piston Adjuster
206-
026 (T87P-2588- A) Klj . 1 ba
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