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does steering wheel shake only when brakes appliad at higher speeds?if so its the front rotors or rotors conforming to runout of front hubs.have rotors turned with on car lathe and make sure lugnuts are torqued to specs.even under the best conditions and service youll be lucky to get 15k without reoccurance.very common on all vehicles with cast iron brake rotors...unfotunately.
The vehicle will need to raised on the left (drivers) side and supported. Remove the tire, then the brake caliper assy. Remove the rotor, then remove the axle nut located in the center of the hub assy. Remove the hub/bearing retaining bolts, and then the hub assy. Some times it is corroded into the steering knuckle assy. and will not seem to come out. If this happens, install the axle nut, and wearing safety glasses, pound onto the hub flange from the inside to the outside, until it comes out of the knuckle assy. Then remove the hub assy. Clean the knuckle hole where the bearing with 120 grit sand paper, so the hub/bearing assy will go into the knuckle without damage. Torque the axle nut to specs. Clean the inside of the rotor, where the hub meets it, so it sits flat against the new hub. Install the rotor, caliper assy. Install the wheel and torque the lug nuts to 100 ft pounds. Road test about 5 miles and recheck the lug nuts.
You will have to remove the brake drum or rotor if it has disc brakes and drive the broken lug out of the drum or rotor. Purchase a new lug from any auto parts store buying the exact same size and drive the new one in. Reinstall the tire/wheel and torque the lug nuts to 100 lb/ft with a torque wrench.
Rotors can not be checked with a straight edge!! They have to be checked with a micrometer to see if they are within factory specs, then have the rotors turned or replaced. However sounds like it's the rotors.
Section 06-03: Brakes, Front Disc
1999 Taurus/Sable Workshop Manual
REMOVAL AND INSTALLATION
Procedure revision date:
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).
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
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.
If original front disc brake rotor is being installed, make sure rotor
braking and mounting surfaces are clean.
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
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).
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
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.
Pump brake pedal prior to moving vehicle to position brake linings.