How to Fix the Brakes on a 2002 Ford Mustang

The Ford Mustang was introduced in 1964 and became known as the 1964-1/2 Mustang. Since then the Ford Mustang has continued to inspire competition among American muscle cars such as the Chevrolet Camaro, Dodge Charger and Pontiac Trans Am. The 2002 Ford Mustang featured a 3.8-liter V-6, capable of producing 190-horsepower. A 260-horsepower 4.6-liter V-8 was available in the 2002 Mustang GT. The 2002 Mustang had front disc brakes, which included calipers, pads and rotors. Replacement of the front brakes should be performed by someone with prior mechanical experience.

Instructions

Loosen the front wheel lug nuts with the tire iron. Raise the front of the Mustang using the low-profile jack, one corner at a time. Place a jack stand beneath both front sub-frame rails, just inward from the lower control arms. Do not place the jack stands beneath the lower control arms because they are unstable. Remove the lug nuts when the vehicle is properly lifted and supported, then remove the front wheels from the Mustang.

Place a set of flat-nose pliers on the rubber brake hose about 1 inch behind the front caliper. This will help prevent fluid loss and lessen brake bleeding times at the end of this project. Remove the banjo bolt from the rear of the brake caliper, then remove the brake hose from the caliper completely.

Remove the caliper bolts from the rear of the caliper with the ratchet and socket, then discard the bolts. Remove the caliper completely from the brake assembly, using a small pry bar if necessary. Remove the old brake pads from the caliper bracket and discard them. Remove the brake caliper anchor plate bolts with the ratchet and a socket, then remove the anchor plate.

Remove the brake rotor retaining clips, if equipped, with needle-nose pliers. Remove the old brake rotor from the front hub by hand. Apply caliper grease to the outboard face of the hub spacer, which the rotor mounts against. Install a new brake rotor, and add one lug nut to a stud to hold the rotor in place. Snug the lug nut up by hand. Spray the outboard and inboard faces of the new rotor with aerosol brake cleaner. Use half of the can to do both sides of one rotor.

Install the brake caliper bracket and tighten the bolts to 95 foot-pounds with a torque wrench and socket. Install the new brake pads onto the caliper bracket. Two of the brake pads have a metal L-shaped protrusion, or wear indicator. The indicator-equipped pads go on the inboard side of each rotor. Apply a light coating of caliper grease onto the shim plates on the rear of the both brake pads.

Install the new brake caliper onto the brake assembly, and tighten the new caliper bolts to 25-foot-pounds for a dual piston caliper, or 65-foot-pounds for a single piston caliper. Use the torque wench and socket to tighten these bolts. Install the new copper crush washers that come with the new caliper, then install the brake line against the back of the caliper. Tighten the banjo bolt to 25-foot-pounds with the torque wrench and a socket.

Repeat Steps 2 through 6 to complete the caliper, pad, and rotor replacement on the second side of the Mustang. Proceed to the brake bleeding section of this article when you have completely installed both sides properly.

Ask your assistant to sit in the drivers seat of the Mustang. Ask him to depress the brake pedal to the floor and hold it. Open the brake bleeder screw on the caliper with an open-end wrench. Allow the air to escape the caliper, then retighten the screw immediately. Ask the assistant to allow the brake pedal to extend back to its upright position. Repeat this step three times per caliper. Check the brake fluid level in the reservoir, and add fluid to the Full mark every time you switch sides.

Ask the assistant to pump the brake pedal about five to 10 times and hold his foot on the pedal. Open the bleeder screw to allow the air to escape the caliper. Repeat this step on each side of the vehicle until only brake fluid comes out of the caliper. Fill the brake fluid reservoir every time you switch sides of the car. Fill the reservoir to the Full mark when you have completely bled both sides of the Mustang.

Install the front wheels onto the Mustang, and snug the lug nuts with a tire iron. Raise the car off of the jack stands, and remove them from beneath the car. Lower the car to the ground, and tighten the lug nuts immediately to 105 foot-pounds of torque, using the torque wrench and a wheel nut socket.