How to Replace the Disc Brakes on a Ford 500

The Ford Motor Company manufactured the Ford 500 from 2005 through 2007. It replaced the Taurus, then was renamed the Taurus in 2008. As did the later-model Taurus, the 500 featured front and rear disc brakes. The front brakes supported 75 percent braking capacity for the car and the rear supplied the rest. Since the rear calipers and pads are smaller, there were a lot of problems with premature brake wear.

The Front Disc Brakes

There are some key differences in performing a front disc brake repair on the Ford 500. Lift the vehicle, but shift into neutral before lifting. This will allow the front wheels to rotate as well as move back and forth for better access to the caliper guide and anchor bolts.

After removing the wheels, remove the two caliper guide bolts from the caliper and then pry the caliper off the rotor. Remove the inboard pad from the caliper piston and remove the outboard pad. Removing the caliper anchor bolts will require a suitable tool such as a breaker bar. Ford recommends discarding and replacing the anchor bolts for reinstallation. The anchor only needs to come off if the rotor is being replaced, but when pads are being replaced, it's always a good idea to replace the rotors as well.

Once the anchor is out of the way, remove the rotor retaining screw and then remove the rotor.

Compress the caliper piston inward using a large C-clamp until the piston bottoms out into the bore.

To install the pads, it's best to purchase a set that come with new rattle clips and hardware. Remove the old clips and hardware and then replace the new ones onto the anchor. Lubricate the mating surface of the clips using an anti-seize compound or high-temp silicone brake lubricant.

Replace the rotor, anchor -- new anchor bolts should be torqued to 81-foot pounds -- pads, and then the caliper. Replace the guide bolts, but apply lubricant to the non-threaded section before reinserting. Tighten the guide bolts to 40-foot pounds.

Replace the wheels and nuts. Torque the nuts to 100-foot pounds.

To seat the pads on the 500, start the engine and then apply 20- to 30-foot pounds of pressure to the brake pedal for one full minute. Shut the engine off and pump the pedal to check for firmness. Always check and adjust the brake fluid level before replacing brakes.

The Rear Disc Brakes

The procedure is similar to replacing the front brakes. A key difference is removing the integrated parking brake cable from the caliper. Another major difference is the caliper pistons. The pistons employ a threaded design and a special tool must be used to work on them. This tool is available for purchase or rental at most parts stores. The left side caliper -- driver's side -- needs to be turned clockwise while pressure to the piston bore is being administered. This can be tricky and may require repeated attempts. The right caliper -- passenger side -- must be turned counterclockwise in the same fashion to compress the piston.

Again, it is recommended to discard and replace the caliper anchor bolts. The torque specifications are the same for the front and rear.