How to Replace a Caliper in a Mercury Cougar

Because the Mercury Cougar is out of circulation, finding replacement parts like brake calipers can be hard. Your best bet is to find complimentary parts from related models, like the Ford Thunderbird. Consult with an expert and verify all parts before performing major service on your Cougar.

Instructions

Removing Old Calipers

1

Remove the tire and wheel assembly once the car is securely raised. Use the "five-star" pattern to remove the lug nuts, removing the nut across from the one previously removed.

2

Disconnect the outer disc brake pad spring clip (also called the anti-rattle clip) from the front caliper. Remove the parking brake's rear cable and conduit from the rear caliper (This will require a pair of pliers).

3

Take the covers off the two locator pins and remove the pins.

4

Unhook the brake hose from its mounting on the strut. Place a pan under the caliper, disconnect the hose from the caliper and allow the fluid to drain. Dispose of the fluid properly.

5

Lift the caliper off the brake rotor and remove the inboard disc brake pad from the caliper. Remove the caliper from the rotor completely.

Installing New Calipers

6

Position the brake hose onto the new caliper and the inboard brake pad into it. Make sure the outboard brake pad is also positioned properly.

7

Install the caliper over the brake rotor and position it onto the anchor plate. Connect the locator pins and attach the pin covers.

8

Attach the outer disc brake pad spring clip to the caliper. Connect the brake hose to the front strut.

9

Connect the spring clip/cable and conduit to the caliper. If attaching the cable and conduit to the rear caliper, operate the parking brake control several times to properly adjust it.

10

Bleed the brake system.

11

Reinstall the wheel and lower the car.

12

Pump the brake pedal several times while stopped to position the brake pads. Then road test the car and check for proper brake operation.

Bleeding the Brake System

13

Clean around the master cylinder fill cap and bleeder screws. Fill the master cylinder with brake fluid to within a quarter inch of the reservoir's top edge.

14

Attach a rubber hose over the bleeder screw Place the hose's other end in a glass jar half-filled brake fluid.

15

Open the bleeder screw a little more than a half turn. Have another person slowly depress the brake pedal, close the screw and wait for the pedal to retract. Repeat this until all air is removed from the system.

16

Top off the reservoir afterward.