How to Remove a 1996 Ford Taurus Front Rotor

The Ford Taurus has lived a rather roller-coaster-like life. It began as one of the most advanced and modern cars of its time, later it shifted to an oval-obsessed monster, then it became downright bland and, finally, Ford deleted it altogether in 2006. In 2008, however, the Taurus returned to replace its replacement the Five Hundred and in 2010 it became a stylish and unique vehicle again. The 1996 Taurus was the first year of the oval-obsessed generation. The 1996 Taurus came standard with front disc brakes, which used a ventilated rotor. When replacing the Tauruss front rotors, it is best to put new pads on at the same time to assure long rotor life.

Instructions

Removal

1

Open the Tauruss hood and remove the master cylinder reservoir cap. Siphon out about half of the brake fluid from the master cylinder with a clean turkey baster and transfer the fluid to a small container.

2

Loosen the front lug nuts with a ratchet and socket. Raise the front of the Ford with a floor jack and position jack stands under the vehicles subframe. Lower the Taurus onto the jack stands. Remove the lug nuts and pull the front wheels off the vehicle.

3

Remove the two caliper-retaining bolts with a ratchet and socket, and pull the caliper off the caliper bracket. Hang the caliper from a nearby suspension component with a bungee strap.

4

Pull both brake pads out of the caliper bracket and position the inner brake pad inside the caliper, so it touches the calipers piston. Position an 8-inch C-clamp over the caliper, so the screw part touches the inner brake pad and the fixed part touches the rear of the caliper. Tighten the C-clamp until it stops tightening to retract the caliper piston. Loosen and remove the C-clamp.

5

Remove the two caliper bracket-retaining bolts and pull the caliper bracket off the Tauruss steering knuckle. Pull the caliper pins from the caliper bracket, using caution as not to break the rubber boot on each caliper pin.

6

Wipe the old grease off the caliper pins with a clean, lint-free cloth. Apply a generous coat of new disc brake grease to the pins and reinsert them into the holes in the caliper bracket. Guide the rubber boot on each pin toward the caliper bracket so each boot seats in its respective groove in the bracket.

7

Pull the rotor off the Tauruss front hub. If the rotor does not pull off easily, lightly tap the rear of it with a rubber mallet to free it.

8

Repeat Steps 3 through 7 to remove the rotor on the other side of the Taurus.

Installation

9

Install a new rotor onto the Tauruss front hub.

10

Set the caliper bracket back onto the Tauruss steering knuckle and hand-tighten the two caliper bracket-retaining bolts. Tighten the caliper bracket-retaining bolts from 65 to 87 foot-pounds with a torque wrench and socket.

11

Press new anti-rattle shims included with the new pads onto the rear of the new brake pads. Slide the new brake pads into the caliper bracket.

12

Remove the caliper from the bungee strap and set it back onto the caliper bracket. Hand-tighten the caliper bolts, then torque them from 23 to 28 foot-pounds with a torque wrench and socket.

13

Repeat Steps 1 through 4 to install the rotor on the other side of the Taurus.

14

Reinstall the front wheels onto the Taurus and hand-tighten the lug nuts. Raise the vehicle off the jack stands with a floor jack and remove the jack stands. Lower the Ford to the ground. Tighten the lug nuts in a crisscrossing pattern from 85 to 105 foot-pounds.

15

Press and release the brake pedal until it feels firm. Check the brake fluid level in the master cylinder reservoir and add DOT3 brake fluid until the level reaches the Max line on the reservoir. Tighten the master cylinder reservoir cap back onto the master cylinder reservoir.

16

Take the small container with old brake fluid to a local automotive fluid recycling center. Many auto parts stores take old brake fluid free of charge.