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How to Replace Front Disc Brakes in a Mercury Villager

by Contributor

Your 2001 through 2005 model Mercury Villager offers convenience and reliability. Offering ease when getting in and out, reliability, and comfort, the Mercury Villager was a good choice for you. To continue enjoying these benefits you need to perform required maintenance such as replacement of the front disc brakes.

Step 1

Park the vehicle on a flat and level surface. Apply the parking brake. Secure the vehicle by wedging something behind the wheels to prevent the vehicle from rolling. Slowly jack the vehicle up, secure it and support it using jackstands.

Step 2

Disengage the master cylinder reservoir cap. siphon brake fluid from the master cylinder reservoir until it is approximately one third full by using a syringe, like a turkey baster. Throw away the old fluid, it will not be reused.

Step 3

Remove the wheel. Using a Torx® ® T-40 bit, remove the bottom guide bolt. Pivot the caliper cylinder body, moving it up to allow access to the brake pads. Using mechanic's wire suspend the caliper cylinder body from the frame. Using a screwdriver, release the outboard brake pad retainers and with another screwdriver disengage the pads. Compress the caliper piston until it is fully seated. This can be completed by using a C-clamp or similar tool and placing it on the inboard brake pad.

Step 4

Compress the caliper piston until it is fully seated using a C-clamp or similar tool place on the inboard brake pad. Install the brake pads. Install the brake caliper assembly. Using a torque wrench, torque the guide pin to 23 to 30 foot/pounds. Reinstall the wheel.

Apply the brake pedal 3 to 4 to seat the brake pads. Check the master cylinder reservoir to ensure that the fluid is at the appropriate level. If necessary, add brake fluid. Bleed the brakes. Test drive the Mercury Villager at slow to moderate speeds to ensure that the maintenance was performed correctly.

Items you will need

  • 2 Flathead screwdrivers
  • C-clamp
  • Brake pads
  • Brake fluid
  • Fyringe or turkey baster
  • Torx® ® T-40 bit
  • Mechanic's wire
  • Torque wrench

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