How do I replace the rotors on my '03 Grand Marquis? Is it as simple as removing the wheels, then the castle-nut behind them, like a lot of older cars? I haven't looked at them yet, but want to get an idea what I'll get into before starting this project....
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Lock handbrake, loosen lug nuts, jack it up and set on axle stands and remove front wheels.
Unbolt the brake caliper, tie it up to the suspension arm with a zip tie etc. Don't let it hang loose on the brake lines. Unbolt the brake rotor from the hub. You might need a friend to stand on the brakes to keep the rotor from spinning.
Once the brake rotor is off, undo the center hub nut (usually a large bolt 22mm or bigger). Keep these in order when you remove them, the castle nut is next (looks like a little castle turret), washers, a lock nut and then finally the bearings are next. Clean out the aperture with a clean cloth.
Regrease the bearings and the inside of the hub. Refit the parts in the right order. Be gentle with the lock nut, it may take a few goes to get this right as it can be too loose or too tight, making the rotor (when it's back on) feel stiff to turn.
Refit the rotor, brake caliper (make sure the brake line is not crimped) and do the same for the other side if it is necessary. Refit wheels and take her for a spin.
To replace rotors and pads, wheel wrench, sockets, hammer, with 4x4, remove wheel,pry pads apart, remove caliper, smack off rotor, and reverse install. 2x4, remove wheel, caliper, hub dust cover, cotter pin, castle nut, and remove rotor and bearings, clean and repack your brgs and replace dust seal, install in new rotor and reverse install. GOOD LUCK, RDJRP
After you get the wheel off; remove brake calipers...do not allow them to hang down - you'll damage the brake lines!
Remove the grease cover at the center of the rotor with a flat blade screw driver. Remove the castle pin and nut, then the rotor should slide off the spindle with very little effort.
To remove the bearing raceways...clean the grease out of the center of the rotor...so you can see what you're doing. Place rotor on a solid bench/cement pad, so you can get a flat chissel/large screw driver to the inside of the rotor...pound the raceway out, working around the rotor in a circle - the raceway needs to come out evenly to avoid damage to the rotor. If you can't get the raceways out - take the rotor to a machine shop that can do it for you (sometimes the auto parts store will help...if there're not busy).
GOES BACK TOGETHER IN REVERSE ORDER:
The best thing to do is get pre-packed bearings, new castle pins and a tub of axle grease.
Remember, put about 1/2 cup/palm full of grease into the center of rotor prior to re-assembly. Also, don't over tighten the wheel...put the castle nut on and finger tighten. slightly tighten with a wrench...ensure the rotor turns freely - must be snug and slight resistance should be noticed. Don't forget the new castle pin.
Section 04-01: Suspension and Wheel Hubs, Front
1996 Taurus, Sable Workshop Manual
REMOVAL AND INSTALLATION
Wheel Hub Bolt
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
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).
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).
Loosen the wheel nuts slightly. Raise the front of the vehicle, and make sure it is securely supported.
Remove the front wheel and tire from front hub.
Remove the split pin, then remove castle nut and washer from the front hub while applying the brake. Remove the caliper mounting bolts, and hang the caliper assembly to one side. To prevent damage to the caliper assembly or brake hose, use a short piece of wire to hang the caliper from the undercarriage.
Remove the wheel speed sensor from the knuckle.
Disconnect the tie rod end ball joint from the knuckle using the special tool (09568-34000).
Remove the split pin.
Remove the castle nut.
Disconnect the ball joint from knuckle using the special tool (09568-34000).
Remove the lower arm ball joint mounting bolts
Remove the strut lower arm mounting bolts
Remove the hub and the knuckle assembly
Reverse the order of the removal procedure.
Remove the wheel and take off your brake caliper. Once you have the wheel off, you will see a dust cap in the center of the wheel. Remove the dust cap by using a pair of channel locks, don't use something to pry it loose as this will cause it to leak grease later. Once you have the dust cap off you will see inside a castle nut held in place with a cotter pin. Remove the pin and unscrew the nut. This will allow the rotor and bearing to come out. Replace the bearing with the new one using a high temp grease to grease them.... IMPORTANT: when you grease the new bearings make sure to grease them thoroughly. Put a glob of grease in the palm of your hand and slowly dab the sides of the new bearings in the grease (this will allow the bearings to be greased on the inside).... Put back together as you found it. NOTE: When tightening the castle nut, tighten it down tight and then release it a quarter turn back before before inserting the pin to hold it back in place. Good luck! Let me know how it goes. PS If when you have the rotor off, you have trouble getting the inside bearing off try this very simple and useful trick: Put the rotor back on the spindle and thread the castle nut on a couple of times. Next **** the rotor across the nut. This will cause the bearing to hang up on the castle nut and simply pop out.
If you have the caliper and retaining rings off the park brake must be holding it. This vehicle has small parking brake shoes that apply to the inside of rotor hat. Try backing off the adjustment and tap the sides of the hat to free them up.