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Replace caliper with old brake pads put 1 bolt in place to hold together while taking a large screwdriver and prying caliper piston so that it compresses piston & block wedge to rear of bracket it should make enough room to install on new brake pads, the other way is to use a large c clamp put 1/4 pice of wood in between c clamp and caliper so you don't damage or Mar the caliper also check YouTube.
The cables usually use a groove and hook system where the Emergency brake cables slide into the hook of the fixture on the Caliper. The assembly must be turned almost 90 degrees to slip the fixture into and out of the channel.
Press the parking brake lever with slip-joint pliers to relieve the tension on the brake cable. Grip the cable's end with locking pliers and disconnect it from the parking brake lever
Apply the emergency brake and block the rear wheels to prevent movement of the car. make sure the car is on a level surface. Jack the front end up and use jack stands to support the car. Leave the floor jack under the side you are working on just in case. Remove the front wheels one at a time and complete one side then the other. There will be two bolts on the inside of the brake caliper that retain it to the backing plate. Remove the bolts and gently pry the caliper off the rotor. If the rotors are worn enough there will be a lip on the outer edge that the pads will have to clear to remove the caliper. Remove the caliper and support the assembly so it does not just hang by the brake line. Remove the old pads. You will need a special tool to push the piston and turn it at the same time. You can rent this tool or borrow one from a parts store with a deposit. This tool is a must. You will never obtain the correct pressure while twisting the piston to engage the threads to turn the piston back into it's bore without it. I would turn the rotors also. You may not see it by the ***** eye, but they may be warped or have fluted edges which will cause a bumping feeling in the brake pedal when you apply the brakes. This is not the same feeling you experience when the ABS system kicks in. These are two different sensations. Pretty simple process. Safety is key here since you have three children and a grandmother that depend on you. You sound pretty determined. Be safe and ask for someone to help you if need be. Good luck.
they r a self adjusting cable....if ur sable has rear drum brakes then adjust the rear shoes...if it has rear disc brakes then u have a faulty rear brake caliper..the parking brake system is also inside the rear brake calipers
Section 06-03: Brakes, Front Disc
1999 Taurus, Sable Workshop Manual
REMOVAL AND INSTALLATION
Brake Shoe and Lining
Removal
Remove brake master cylinder filler cap (2162). Check fluid level in brake master cylinder reservoir (2K478) . Remove brake fluid until brake master cylinder reservoir is half full. Discard removed fluid.
Raise vehicle on hoist.
Remove wheel and tire assembly from front disc brake rotor mounting face. Use care to avoid damage or interference with disc brake caliper (2B120) , front disc brake rotor shield (2K004) or front wheel knuckle (3K185) .
Remove rear brake pin retainers (2N386).
NOTE: It is not necessary to disconnect hydraulic connections.
Lift disc brake caliper from front disc brake caliper anchor plate (2B292) and front disc brake rotor (1125) . Do not pry directly against metal caliper piston or damage will occur.
NOTE: To prevent damage, do not allow disc brake caliper to hang by the front brake hose (2078) .
Position disc brake caliper out of the way.
Remove inner outer brake shoe and lining (2001) assembly from front disc brake caliper anchor plate .
Inspect both rotor braking surfaces. Minor scoring or buildup of lining material does not require machining or replacement of front disc brake rotor.
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remove the 2 pins, #10 in pic. Usually has a dust cover over pin accessopening. Usually torx haed or hex head bolts (pins).
Remove the wheel, remove the 2 bolts holding on the caliper to the caliper carrier. You will need a large C-Clamp or a cailper piston tool. Place an old brake pad against the piston in the caliper and use the C-Clamp to push the brake pad against the piston to collapses the piston into the caliper. Also open the master cylinder cap and place a towel around the area to catch any brake fluid that would come out of the master cylinder as you collapes the piston, this is normal, but doesn't always happen, depending on the level of fluid in the master cylinder. Install the new pads and reinstall the caliper and wheel. Make sure you pump the brake pedal a few times before you take off, to get the pads against the rotor.
1999 Taurus/Sable
Section 06-03: Brakes, Front Disc
1999 Taurus/Sable Workshop Manual
REMOVAL AND INSTALLATION
Procedure revision date:
06/25/1998
Disc
Removal
Raise vehicle on hoist.
Remove wheel and tire assembly. Be careful to avoid damage or interference
with caliper bleeder screw fitting and front disc brake rotor shield (2K004).
CAUTION: Handle
front disc brake rotor (1125) and disc brake caliper (2B120) assembly in such a
way as to prevent deformation of front disc brake rotor , and nicking,
scratching or contamination of brake linings/rotor surfaces. NOTE: To prevent damage, do not allow disc brake caliper to hang by the
front brake hose (2078) .
Remove caliper anchor plate bolts and discard. Position disc brake caliper
out of the way. Prevent separation of caliper housing from anchor bracket
because contamination of guide pin journals can occur.
NOTE: If excessive force must be used during front disc brake rotor
removal, the front disc brake rotor should be checked for runout prior to
installation.
If additional force is required to remove front disc brake rotor , apply Rust
Penetrant and Inhibitor F2AZ-19A501-A or equivalent meeting Ford specification
ESR-M99C56-A on front and rear rotor/hub mating surfaces. First, strike front
disc brake rotor between lug bolts (1107) with a plastic hammer. If this does
not work, attach 2-3 Jaw Puller 205-D027 (D80L-1013-A) or equivalent and remove
front disc brake rotor . Remove front disc brake rotor from wheel hub (1104)
assembly by pulling it off the lug bolts.
Installation
If original front disc brake rotor is being installed, make sure rotor
braking and mounting surfaces are clean.
CAUTION: Failure
to clean rust and foreign material from rotor and hub mounting faces when
installing new or old front disc brake rotors will result in high rotor runout,
which will speed up the development of brake roughness shudder
vibration.
Apply a small amount of Silicone Brake Caliper Grease and Dielectric Compound
D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to pilot
diameter of front disc brake rotor.
Install front disc brake rotor on wheel hub assembly.
Install disc brake caliper and new caliper anchor bracket bolts on front disc
brake rotor . Tighten caliper anchor bracket bolts to 88-118 Nm (65-87 lb-ft).
CAUTION: Failure
to tighten lug nuts (1012) in a star pattern may result in high rotor runout,
which will speed up the development of brake roughness, shudder and
vibration.
Install wheel and tire assembly on vehicle. Tighten lug nuts to 115-142 Nm
(85-104 lb-ft) using Rotunda Accutorq® Lug Nut Socket 164-R0303 or equivalent on
a 1/2 inch air impact wrench, or use a torque wrench.
Lower vehicle.
Pump brake pedal prior to moving vehicle to position brake linings.
Section 04-01: Suspension and Wheel Hubs, Front
1996 Taurus, Sable Workshop Manual
REMOVAL AND INSTALLATION
Wheel Hub Bolt
Removal
Raise vehicle on hoist.
Remove wheel and tire assembly. Refer to Section 04-04 .
Remove disc brake caliper (2B120), and front disc brake rotor (1125). Refer to Section 06-03 .
Brake Shoe and Lining
Removal
Remove brake master cylinder filler cap (2162). Check fluid level in brake master cylinder reservoir (2K478). Remove brake fluid until brake master cylinder reservoir is half full. Discard removed fluid.
Raise vehicle on hoist. Refer to Section 00-02 .
Remove wheel and tire assembly from front disc brake rotor mounting face. Use care to avoid damage or interference with disc brake caliper (2B120), front disc brake rotor shield (2K004) or front wheel knuckle (3K185).
Remove rear brake pin retainers (2N386). ( I think it is a T 40 torx bit you need)
NOTE: It is not necessary to disconnect hydraulic connections.
Lift disc brake caliper from front disc brake caliper anchor plate (2B292) and front disc brake rotor (1125). Do not pry directly against metal caliper piston or damage will occur.
Position disc brake caliper out of the way and support with wire to avoid damaging the disc brake caliper and front brake hose (2078).
Remove outer brake shoe and lining (2001) assembly from front disc brake caliper anchor plate.
Remove inner brake shoe and lining assembly.
Position lug bolt (1107) to clear front wheel knuckle (3K185).
Remove lug bolt from wheel hub (1104).
Installation
Install lug bolt into wheel hub.
Using a lug nut (1012), seat wheel hub bolt into wheel hub.
Install front disc brake rotor and disc brake caliper. Refer to Section 06-03 .
Install wheel and tire assembly. Tighten lug nut to 115-142Nm (85-104 lb-ft).
I have the calipar brackets off and the rotors won't come off!!!
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