How to Remove the Rear Caliper From a 2001 Cougar

The Mercury Cougar enjoyed a long run lasting from its initial release in 1967 until its first elimination after the 1997 model year. In 1999, Mercury released an all-new and completely redesigned Cougar, straying far from its full-size sedan roots. The new Cougar had a sports car design, look and feel to it. The 2001 Cougar came standard with front disc brakes and rear drum brakes. Mercury added rear disc brakes as a part of the "V-6 Sports Group" package on the 2001 Cougar. After removing and replacing the rear caliper on the 2001 Cougar, you must bleed the brake system.

Instructions

1

Loosen, but don't remove, the rear lug nuts, using a ratchet and socket. Raise the rear of the Cougar, using a floor jack, and position jack stands under the rear suspension. Lower the Cougar onto the jack stands. Remove the lug nuts and the rear wheels.

2

Grip the end of the parking brake cable with a set of pliers and pull it outward until there is enough clearance to slide the cable through the slot in the brake caliper. Slide the parking cable through the slot in the caliper to free the cable. Remove the parking brake conduit from the caliper and allow the parking brake cable to hang free.

3

Position a drain pan under the brake hose on the rear of the caliper. Remove the banjo bolt securing the brake hose to the caliper and discard the metal washers -- ensure that you use new washers. Pull the brake hose from the caliper.

4

Remove the cotter pin from the guide pin on the lower caliper arm, using pliers, and pull the guide pin from the lower caliper arm.

5

Remove the rubber cover from the upper caliper-locating pin and remove the pin using a ratchet and hex-bit socket. Pull the caliper off the rear of the Cougar.

6

Compress the caliper piston using a rear caliper tool, if reinstalling the old caliper. This process varies, depending on the type of tool used, so refer to the tool's instructions for specific instructions. Skip this step if you are replacing the caliper with a new one.

7

Set the caliper on the rear brake system of the Cougar. Insert the guide pin through the lower caliper arm and insert the cotter pin through the guide pin. Bend the cotter pin legs in opposite directions, using pliers, to lock it in place.

8

Insert the rear caliper-locating pin and tighten it to 30 foot-pounds, using a torque wrench and socket.

9

Set new metal washers -- included with a new caliper -- on the brake hose. Insert the banjo bolt through the end of the brake hose and hand-tighten the banjo bolt into the rear of the caliper. Torque the banjo bolt from 31 to 39 foot-pounds with a torque wrench and socket.

10

Press the parking brake conduit back into the mounting groove on the rear of the caliper. Pull the end of the parking brake cable with pliers until you have the clearance to slide the cable into the groove on the caliper. Slide the parking brake cable into the groove on the rear of the caliper and seat the end of the parking brake cable into the groove.

Bleeding the Cougar's Brakes

11

Loosen the Cougar's front lug nuts and raise the front of the vehicle, using a floor jack. Position jack stands under the Cougars subframe and lower the front of the vehicle onto the jack stands. Remove the lug nuts and pull the front wheels from the Cougar.

12

Fill a small container with about three inches of new DOT 3 brake fluid.

13

Locate the brake bleeder valve, the quarter-inch, brass valve, on the rear of the right rear caliper. Attach a 2-foot long, quarter-inch rubber hose to the bleeder valve.

14

Insert the free end of the rubber hose in a small, clear container, so brake fluid covers the free end of the hose. Ensure this end remains submerged throughout the entire bleeding process to avoid backfilling the line with air.

15

Instruct an assistant to press and release the brake pedal about 10 to 15 times and then hold steady pressure on the pedal. As the assistant holds the pedal, loosen the bleeder valve with a combination wrench. Observe as fluid and some air bubbles enter the fluid in the clear container. Tighten the bleeder valve.

16

Repeat Step 4 until only fluid and no air bubble comes from the rubber hose.

17

Bleed the remaining three brake calipers by repeating Steps 3 through 6 in the following order: left front, left rear and right front. Check the brake fluid level in the master cylinder and refill it with new DOT 3 brake fluid, as needed.

18

Reinstall all four wheels and hand-tighten the lug nuts. Raise the front of the Cougar off the jack stands, with a floor jack, and lower it to the ground. Tighten the front lug nuts, in a crisscross pattern, to 94 foot-pounds with a torque wrench and socket. Raise the rear of the Cougar off the jack stands, remove the jack stands and lower it to the ground. Tighten the rear lug nuts, in a crisscross pattern, to 94 foot-pounds.

19

Check the fluid level in the brake master cylinder and add DOT 3 fluid until the level is between the "Min" and "Max" lines on the master cylinder.

20

Take any old brake fluid in the small container to a local automotive fluid recycling center. Many auto parts store take old fluids free of charge.