How to Replace the Disc Brakes on a 1994 Mercury Sable

The Mercury Sable was introduced for the 1986 model year, along with its sister car the Ford Taurus. The Mercury Sable continued in production from 1986 until 2009, when it was discontinued for a new line of Mercury vehicles. The 1994 Mercury Sable was equipped with the option of a 3.0-liter V-6 or a 3.8-liter V-6 engine. The disc brakes on the 1994 Mercury Sable include the front brake calipers, rotors, and brake pads. Replacement of the brake calipers is an option for completely replacing the disc brakes on the 1994 Sable. The process is known as C.P.R. or calipers, pads and rotors.

Instructions

Loosen all of the lug nuts, but do not remove them. Lift the front of the Sable using jack with 2-ton or greater capacity. Place jack stands beneath the front frame rails or engine cradle frame, just inside the inner lower control arm ends. Remove the lug nuts completely from the front of the vehicle and remove the front wheel and tire assemblies.

Remove the front caliper bolts using a 3/8-inch drive ratchet and socket to turn the bolts counterclockwise. The caliper bracket bolts are located behind the brake caliper, on the inside of the wheel well. Slide the caliper halfway off the brake rotor using a pry bar or large, flat-head screwdriver.

Insert the pry bar into the hole in the middle of the caliper and pry the rear or inside brake pad away from the rotor. This procedure will compress the caliper piston. Continue prying the brake pad away from the back of the rotor until the caliper piston is completely compressed. If you are replacing the brake calipers, disregard this step completely.

Remove the caliper mounting bracket from the brake assembly, using a 3/8-inch drive ratchet to remove the mounting bolts. Removing the bracket separately from the caliper will allow for easier access to install new brake pads on an old caliper, or to install a brand-new caliper and brake pad set.

Remove the caliper and bracket by hand from the brake assembly and set the caliper onto the lower control arm. This is the large, metal piece underneath and behind the brake rotor and steering knuckle assemblies. You can hang the rotor from one of the strut spring rungs using a wire coat hanger if you so choose. Remove the brake rotor by hand.

Place a brake line clamp on the rubber line between the rear of the brake caliper and the frame of the Sable. Setting the clamp as close to the rear of the caliper as possible will decrease the amount of time needed to bleed the brakes at the end of this project. Remove the banjo bolt from the rear of the caliper, or the bolt that holds the brake line onto the back of the caliper. Use a 3/8-inch ratchet and socket to turn the bolt counterclockwise in order to remove it. Remove the brake line from the back of the caliper. Immediately discard the brake caliper into a drain pan. If you are not replacing the brake caliper, skip this step and go directly to Step 7.

Install the new brake caliper onto the brake line and insert the banjo bolt. Hang the new caliper from the front strut spring, using a wire coat hanger. Tighten the banjo bolt and rear brake line onto the caliper between 25 and 40 foot-pounds of torque, using a certified 3/8-inch drive torque wrench and socket. Remove the brake hose clamp form the rear of the brake caliper, if necessary.

Install the new brake rotor by hand and tighten one lug nut down onto the face of the new rotor to hold it in place during installation of the rest of the brake assembly. Install the caliper mounting bracket back onto the brake assembly and tighten the mounting bolts with a 3/8-inch drive torque wrench and socket to between 60 and 80 foot-pounds of torque. Remove the lug nut from the face of the rotor once you have the caliper bracket completely installed.

Install new brake pads into the caliper mounting bracket, making sure the wear indicator on the brake pads are on the inside, or back of the rotor. The wear indicator is a small, metal protrusion off the brake pads, with a 90-degree bend. There are two brake pads with indicators and two without in a set of pads. Lubricate the back of the brake pads, using certified caliper grease. Apply a thin film of grease onto the backing plates of the pads to decrease initial brake squeal caused by new brakes.

Install the caliper over the caliper bracket and rotor. Tighten the caliper mounting bolts to between 35 and 40 foot-pounds of torque, using a certified 3/8-inch drive torque wrench and socket.

Repeat steps 2 through 10 to complete the disc brake replacement on the second side of the Sable. Leave the wheels off the vehicle until you have completely installed both sides with new disc brakes and you have completed the next section of this project.

Lie or kneel near one of the front calipers. Visually inspect and locate the bleeder screw on the top-rear of the brake caliper. Instruct your assistant to sit in the driver's seat and to pump the brake pedal until the pedal stiffens up. If the brake pedal does not immediately stiffen, simply ask your assistant to remove his foot completely from the pedal and let you know when pedal returns to its topmost resting position.

Open the bleeder screw one and a half turns with a 3/8-inch ratchet and deep well socket. Instruct your assistant to depress the brake pedal -- slowly -- completely to the floor, and to say the word "down" when the brake pedal is at the bottommost point. Tighten the brake bleeder screw shut when you hear the word "down." Using the words "up" for when the pedal is up at the top or pumped up completely, and "down" for when the pedal is to the floor of the Sable will greatly decrease the chance of any miscommunication during this bleeding procedure.

Repeat the pumping of the brake pedal and the bleeding process at least three times per side on the Sable. When you have completely bled the brakes, the brake pedal will be stiff and rigid when pumped up. Bleeding the brakes removes air pockets in the brake system. Visually inspect and fill your brake fluid reservoir under the hood of the Sable, after you have bled the front brakes completely.

Install the front wheels onto the Sable and tighten the wheel lug nuts until they are snug against the face of the wheel. Raise the Sable with a 2-ton jack and remove the jack stands from beneath the Sable. Lower the car to the ground completely and tighten the wheel lug nuts between 90 and 110 foot-pounds of torque using a certified torque wrench and wheel nut socket.