How to Change 1996 Taurus Brake Rotors

Ford Motor Company introduced the Taurus in 1986. The 1996 Ford Taurus was equipped with four different versions of a 3.0-liter V-6, including a DOHC and a Flex-Fuel 3.0-liter version. The 1996 Taurus SHO was available with a 3.4-liter V-8 engine. Replacing the front rotors on the 1996 Taurus requires removal of the entire brake assembly. Replacement of the brake pads is essential to creating a good mating surface for the new rotors. This project should be performed by someone with prior mechanical experience.

Instructions

1

Raise the hood of the Taurus. Check the level of the brake fluid reservoir. The fluid level needs to be about 1/2-inch below the "Full" mark to safely complete this project. Remove brake fluid with a turkey baster or small bottle siphon if necessary, to lower the brake fluid level to 1/2-inch below the "Full" mark on the reservoir.

2

Loosen the front lug nuts on the Taurus, using a tire iron. Raise the front of the car with a jack. Place jack stands beneath the front frame of the car. Lower the car onto the stands. Remove the front lug nuts completely, then remove the front wheels from the car.

3

Remove the caliper bolts from the rear of the caliper, using a 3/8-inch drive ratchet and socket. Remove the caliper, using a pry bar, if needed. Hang the caliper from the front strut coil spring with a metal clothes hanger or rod. Do not let the caliper hang from the rubber hose between the caliper and the frame.

4

Remove the outboard brake pad from the caliper bracket and discard it. Remove the inboard pad from the caliper bracket and place it against the caliper piston, on the inside rear of the caliper. Install a large C-clamp around the inboard brake pad and the rear of the caliper. Tighten the C-clamp until the caliper piston is completely compressed. Remove the C- clamp and inboard brake pad when you are finished compressing the caliper.

5

Remove caliper mounting bracket from the rear of the rear of the brake assembly, using a 1/2-inch drive ratchet and socket to remove the mounting bolts. Remove the rotor from the face of the hub, by hand.

6

Install the new brake rotor and spin a lug nut onto one of the studs to hold the rotor in place. Spray both sides of the new rotor thoroughly to remove the factory-sprayed-on rust-inhibitor oil. You should use about half of the can on one rotor. Install the caliper bracket, then tighten the bolts to 95 foot-pounds with a 1/2-inch torque wrench and socket.

7

Install the new brake pads onto the caliper bracket, and lightly coat both backing plates with caliper grease. Remove the slide pins from the back of the caliper, by hand. Pack the rubber boots on the back of the caliper with caliper grease. Install the pins back into the caliper, by hand. Install the caliper over the brake assembly, then tighten the bolts to 24 foot-pounds with a 1/2-inch drive torque wrench and socket.

8

Repeat Steps 2 through 6 to replace the pads and rotors on the opposite side of the Taurus. Double-check all mounting bolts to ensure proper torque on both sides of the car. Install the front wheels on the Taurus, then snug the lug nuts with a tire iron. Raise the car off the jack stands, then remove the stands from beneath the car. Lower the car to the ground and tighten the lug nuts to 100 foot-pounds, using a 1/2-inch drive torque wrench and wheel nut socket.

9

Add brake fluid to the reservoir under the hood, if needed. Install and tighten the reservoir cap. Sit in the driver's seat of the car and pump the brakes several times slowly. If the brake pedal does not stiffen up after five or six pumps, stop pumping and bleed the brakes on the Taurus.