2003 FORD MUSTANG wheel

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
12003 Mustang Workshop Manual
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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
32003 Mustang Workshop Manual
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REMOVAL AND INSTALLATION
Pads
Removal
1. Use a suitable suction device to lower the brake fluid level in the master cylinder reservoir.
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. Inspect the pads for wear or contamination, install new if worn to or past specification.
5. CAUTION: Do not allow the rear disc brake caliper (2552) to hang from the rear
wheel brake hose (2A442).
Remove the rear disc brake caliper bolts and position the caliper aside.
6. Remove the brake pads.
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
42003 Mustang Workshop Manual
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1.
CAUTION: Install the brake pads in full axle sets. Do not install new brake pads on
only one side of vehicle.
Install the new slipper and brake pads.
2. Position the caliper on the anchor plate and install the bolts.
3. Install the wheel and tire assembly. For additional information, refer to Section 204 - 04 .
4. Lower the vehicle.
5. WARNING: Use of any other than approved DOT 3 or DOT 4 brake fluid will cause
permanent damage to components and will render the brakes inoperative.
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 or plastic surfaces. If brake fluid is
spilled onto a painted or plastic surface, immediately wash it with water.
Check the fluid level at the master cylinder. Add fluid if necessary.
6. WARNING: Pump the brake pedal several times to make sure the caliper piston is
extended to its operating position. Failure to follow these instructions may result in
personal injury.
Verify correct brake operation. Klj . 3 ba
42003 Mustang Workshop Manual
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REMOVAL AND INSTALLATION
Brake Caliper Support Bracket
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. CAUTION: Do not allow the rear disc brake caliper (2552) to hang from the rear
wheel brake hose (2A442)
Remove the rear disc brake caliper bolts and position the caliper aside.
4. Remove the brake pads.
5. Remove the rear disc support bracket (2B511) bolts and bracket.
SECTION 206-
04: Rear Disc Brake 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
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PINPOINT TEST B: PARKING BRAKE WILL NOT RELEASE to Section 100 - 02 .
z Inspect for broken or binding parking
brake cables or broken guide clips.
z Is there a parking brake cable
concern? INSTALL a new parking brake cable as
necessary. TEST the system for normal
operation.
No
GO to
A2 .
A2 CHECK THE PARKING BRAKE
CONTROL z
Operate the parking brake control.
z Does the parking brake control
operate smoothly? Yes
INSTALL a new parking brake lever. RESTORE
vehicle and TEST the system for normal
operation.
No
REPAIR the binding condition in the parking brake
control. TEST the system for normal operation.
Test Step Result / Action to Take
B1 CHECK PARKING BRAKE CONTROL
z
Raise and support the vehicle. Refer to
Section 100 - 02 .
z Release parking brake by pulling
upward on hand lever and pushing
release button.
z Did parking brake release? Yes
GO to
B2 .
No
INSTALL a new parking brake control.
RESTORE the vehicle and TEST the system for
normal operation. B2 CHECK PARKING BRAKE CABLES
z
Loosen tensioner. Refer to Parking Brake Cable Tension Release in this
section.
z Move the gearshift lever to NEUTRAL
position.
z Rotate rear wheels by hand.
z Did rear wheels turn freely? Yes
GO to
B3 .
No
INSTALL new parking brake cables. RESTORE
the vehicle and TEST the system for normal
operation. B3 CHECK REAR PARKING BRAKE
LEVERS z
Disconnect parking brake levers one at
a time.
z Rotate wheel affected by disconnected
parking brake lever.
z Did wheel turn freely? Yes
INSTALL a new parking brake lever. RESTORE
vehicle and TEST the system for normal
operation.
No
REPAIR or INSTALL a new rear brake
component if worn or damaged. TEST the
system for normal operation. Klj . 2 ba
32003 Mustang Workshop Manual
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GENERAL PROCEDURES
Parking Brake Cable Tension Release
1. CAUTION: If any component in the parking brake system requires repair or if the
rear axle housing (4010) is removed, the cable tension must be released.
Place the parking brake control (2780) in the released position.
2. Remove the console. For additional information, refer to Section 501 - 12 .
3. With an assistant inside the vehicle, raise and support the vehicle. For additional information, refer to Section 100 - 02 .
4. Pull the parking brake cable and equalizer rearward.
5. CAUTION: Do not remove the steel pin until the parking brake cable and
equalizer/rear cable and conduits are connected to the parking brake control. Pin
removal releases the tension in the ratchet wheel causing the spring to unwind and
release tension. Insert a steel pin through holes in the lever to the ratchet wheel. SECTION 206-
05: Parking Brake and Actuation 2003 Mustang Workshop Manual Klj . 1 ba
22003 Mustang Workshop Manual
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