Troubleshooting the Increased Brake Pedal Travel in a '96 Ford Taurus

The Ford Taurus was introduced in 1986. The 1996 Ford Taurus was available as a sedan and as a station wagon. The 1996 Taurus was equipped with a 3.0-liter V-6 engine in the base model. A total of four-different 3.0-liter engines were options in the 1996 Taurus, as well as a 3.4-liter V-8 in the SHO. The brake system in the 1996 Taurus consisted of front disc brakes and rear drum brakes as standard. Some trim packages were available with four-wheel disc brakes. Excess brake pedal travel can be caused by several possible symptoms.

Instructions

1996 Ford Taurus: Brake Inspection Basics

1

Raise the hood on the Taurus. Visually inspect the brake fluid reservoir, in the driver's rear side of the engine compartment. The brake fluid should be at the "Full" mark on the semi-transparent reservoir. If the brake fluid is low, this could be an indicator of a problem with your brakes. If the reservoir is full and you have excess travel in the pedal, your brake system may need to be bled of the air in the system. If the reservoir is below the "Full" mark, proceed to Step 2.

2

Loosen the front wheel lug nuts with a tire iron. Raise the front of the Taurus using a jack. Set jack stands beneath the front sub-frame on either side of the engine. Remove the front wheel lug nuts completely, then remove the front wheels.

3

Lay near the front of the vehicle, and ask your assistant to gently pump the brake pedal. Listen for any slight hissing noise, and look for any brake fluid leaking from the brake system in the front of the car. Move your body down the driver's side of the car toward the rear. Ask your assistant to pump the brake pedal again. Look for any fluid leaking or puddles collecting beneath the car. Any puddles indicate you have a brake line leak, which you will need to fix immediately.

4

Move to the rear of the vehicle and look on the inside of both rear wheels, as well as near the rear axle housing. If the inside of either rear wheel is saturated in brake fluid, you have a wheel cylinder or fitting leak near the rear wheel. If you notice fluid leaking or a puddle building near the rear axle, you have a rear line leak. Have either fixed immediately.

5

Inspect the front brake pads. Place a tape measure against the inboard and outboard faces of each rotor, and measure the brake pad thickness. If the brake pads are less than 1/8 inch thick, then the brake pads need to be replaced. Measure across the top of the brake rotor with the tape measure. If the rotor is less than 15/16 inch thick, then the rotor needs to be replaced. Worn brake parts can cause excess travel in the brake pedal. Replace the pads or the rotors and pads together if needed.

6

Install the front wheels back onto the Taurus, and snug the wheel nuts with a tire iron. Raise the front of the car off of the jack stands, then remove the jack stands from beneath the car. Lower the Taurus to the ground. Immediately torque the front wheel lug nuts to 100 foot-pounds with a 1/2-inch-drive torque wrench and a socket.

7

Loosen the rear wheel lug nuts with a tire iron. Raise the rear of the car with a jack, then place jack stands behind both tires, underneath the rear axle housing. Place the jack stands as far apart as possible to increase stability. Remove the rear wheel lug nuts, then remove the rear tires completely.

8

Inspect the rear brake pads and rotors if your Taurus has four-wheel disc brakes. The brake pads should be no less than 1/8 inch thick. The rear brake rotors should be no less than 1/2 inch thick. Replace the rear pads, or the rotors and pads if needed. If you have drum brakes on the rear, skip this step and proceed to Step 9.

9

Pull the small rubber stopper out of the bottom of the backing plate on the rear brakes. Insert a flat head screwdriver into the hole in the backing plates and spin the star-wheel or self adjuster downward. Gently tap the front faces, then the sides of the brake drums with a hammer. Remove both brake drums from the rear of the Taurus.

10

Visually inspect the brake shoes for excess wear. Measure the brake shoe lining, and replace the shoes if they are less than 1/16 inch thick. Measure across the inside face of the brake drum. The inner diameter of the brake drum should be no more than 8-7/8 inches wide if the Taurus is a sedan, or 9-13/16 inches wide it is a station wagon. If the inner drum diameter is larger than the given numbers, the drums and shoes need to be replaced, along with the brake hardware. Worn parts will cause excess brake pedal travel.

11

Bleed the entire brake system if your inspection of the brake parts determines that the brakes are in good condition. Have your assistant help you bleed the brake system, or take your car to a professional to have the brake system bled.