2003 FORD MUSTANG brake

GENERAL PROCEDURES
Runout Check —
Brake Disc and Hub
CAUTION: The brake disc (1126) runout specification must be met to ensure correct brake
performance without roughness complaints.
CAUTION: Do not install brake discs that are less than the minimum thickness specified.
Do not machine a brake disc below the minimum thickness specification.
NOTE: When installing brake discs, always align the painted match marks on the brake discs with
those on the front hub or rear axle.
NOTE: When installing brake discs, always apply anti- seize lubricant to the brake disc-to-front hub or
to the brake disc- to-rear axle mating surfaces.
1. Do not remove the tire and wheel assembly. Tighten the wheel nuts to specification with a torque stick or torque wrench.
2. Raise and support the vehicle.
3. Assemble the Brake Measurement Kit, using the spherical tip extension.
4. Locate an opening on the inboard side of the dust shield that will allow the dial indicator tip to be positioned at least 5 mm (0.2 inch) from the outer edge of the brake disc.
5. NOTE: Do not clamp the gauge set to a vehicle component separated from the brake disc by a
flexible joint, such as a ball joint or body mount.
Clamp the Brake Measurement Kit on the vehicle, making sure the flexible indicator arm and
probe tip do not touch the dust shield or tire while rotating.
6. NOTE: For rear wheel measurement only, have an assistant push in on the wheel cover or axle
shaft center while rotating the wheel.
Rotate the wheel for six revolutions, and record the total indicated runout.
SECTION 206-
00: Brake System — General Information 2003 Mustang Workshop Manual Special Tool(s)
Brake Measurement Kit
134-R0199 or equivalent
Material Item Specification
High Temperature Nickel Anti-
Seize Lubricant
F6AZ-
9L494- AA ESE-
M12A4-
A Klj . 1 ba
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7. If the total indicated runout exceeds the maximum specification, remove the brake disc. For
additional information, refer to Section 206 - 03 for front or to
Section 206 - 04 for rear.
8. Clean the brake disc mounting face of dirt, rust and foreign material.
9. For front wheels, measure and record the total indicated runout of the hub face outside the stud circle.
10. Install a new front hub if the total indicated runout exceeds the maximum specification. For additional information, refer to Section 204 - 01 .
z Repeat the hub runout measurement.
11. NOTE: Clean the axle flange surface before measuring.
NOTE: For rear wheels, press inward on the axle shaft while measuring the rear axle runout.
For rear wheels, measure and record the total indicated runout at a point on the axle shaft
outside the stud circle.
12. If the total indicated runout exceeds the maximum specification, inspect the rear axle. For additional information, refer to Section 205 - 00 . Repair as necessary.
z Repeat the rear brake disc runout measurement. Klj . 2 ba
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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
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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
72003 Mustang Workshop Manual
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