Ford Mustang Brake Kits
Contents
1. Figure 2 3 Remove the Hose Bracket from the body using a 10mm wrench or socket Retain the bolt for later use Refer to Figure 3 Note The bracket will remain on the stock brake line and will not be reused Figure 3 1306 R19010030 AB_ 093009 Page 6 of 20 1 800 59 ROUSH THE ART OF PERFORMANCE ENGINEERING 4 The middle section of the Mustang front wheel stock brake line is held in place by a line locator attached to a bracket on the strut Remove the line locator bolt using a 10mm wrench or socket Refer to Figure 4 Retain the bolt for later use Note The line locator will remain on the stock brake line and will not be reused Figure 4 Remove Stock Caliper amp Rotor 1 Remove the two stock caliper bolts using a 15mm wrench or socket Discard these bolts Refer to Figure 5 7 sa F i ee Figure 5 1306 R19010030 AB_ 093009 Page 7 of 20 1 800 59 ROUSH ROUSH HE OF PERFORMANCE ENGINEERING 2 Remove the caliper with the stock brake line attached Refer to Figure 6 There may be some leakage from the open end of the brake line Figure 6 3 Remove the stock rotor Refer to Figure 7 Note It may be necessary to strike the outer edge of the rotor with a non marring mallet if corrosion prevents the rotor from simply being pulled off If so loosely thread a wheel nut on one of the studs first to prevent the rotor from falling when it comes free Figure 7 1306 R19010030 AB_ 093002. THE ART OF PERFORMANCE ENGINEERING Ford Mustang Brake Kits Kit R19010027 4 Piston Caliper amp 14 Two Piece Rotor Complete Kit Kit R19010048 6 Piston Caliper amp 14 Two Piece Rotor Complete Kit Application 2005 2011 Ford Mustang Installation Instructions Before installing your ROUSH Performance Product s read through the entire installation procedure and check to make sure all items are present Contact ROUSH Customer Service at 1 800 59 ROUSH weekdays from 9 00 AM to 5 00 PM EST with any questions regarding fit missing parts or instructions that are unclear to you Note Use of these components will require 18 Wheels minimum It is the responsibility of the customer to verify that their wheels will fit Note The factory supplied Temporary Spare Tire will no longer fit the front of the vehicle with this kit If you have a flat front tire we recommend placing the mini spare on the back and transferring an 18 inch wheel to the front Packaging List for Front 4 Piston Brake Kit Part Description Part Number Qty Front 4 Piston Brake Kit with 2 Piece Rotor R19010027 1 4 Piston Caliper Front RH pRIsorooze f1 Adapter Brackets T Piston Sissy R19010014 Front Brake Peds instaled on Calpers Rteot0023 1 Brake Dust Shields Front Brakes R19010017 2 Hardware Kit ROUSH Front Brakes R19010015 1 Braided Brake Lines Cd LHBrakeLineBracket o o ooo y Jt RHBrakeLineBracket CE aa
3. 19 Torque to 17 Nm 150 I b in Figure 19 1306 R19010030 AB_ 093009 Page 15 of 20 1 800 59 ROUSH ROUSH HE OF PERFORMANCE ENGINEERING 7 Position the caliper end of the brake hose so that it is approximately 45 degrees from vertical tilted toward the center of the rotor Refer to Figure 20 Torque the banjo bolt fitting to 19 Nm 168 Ib in Figure 20 Secure the ABS Wiring 1 Run one High Temp Cable Tie through one Rubber Tube Segment Loop the cable tie around the protective rubber sleeve portion of the ABS wire and back through the tube segment Refer to Figure 21 Figure 21 1306 R19010030 AB_ 093009 Page 16 of 20 1 800 59 ROUSH THE ART OF PERFORMANCE ENGINEERING 2 Engage the wire tie ends around the Braided Brake Hose and pull tight Cut off the excess wire tie Repeat for the second ABS protective rubber sleeve Refer to Figure 22 Figure 22 Bleed Brakes Warning Do not let the brake fluid drain until the Master Cylinder is emptied If the Master Cylinder does empty the brake system will have to be bleed by a certified brake technician Do not turn the ignition on until brake bleeding is fully complete 1 Complete the installation of both sides before bleeding the system 2 Refer to the factory service manual for basic brake bleeding Instructions 3 Bleed the brakes using an 11mm wrench to loosen the bleed screws in the following sequence 1 Right outboard bleed screw 2 Right in
4. 9 Page 8 of 20 1 800 59 ROUSH THE ART OF PERFORMANCE ENGINEERING 4 Remove the three retaining bolts holding the dust shield in place using a 10mm wrench or socket Set aside bolts for later use Refer to Figure 8 Figure 8 1306 R19010030 AB_ 093009 Page 9 of 20 1 800 59 ROUSH THE ART OF PERFORMANCE ENGINEERING Assembly 1 Place the ROUSH Dust Shield into place over the hub with the cut out portion to the rear side of the hub and the pockets for the tie rod end facing out Refer to Figure 9 Secure with the bolts removed from the factory dust shield Torque the bolts to 10 Nm 89 Ib in Tie rod pockets Figure 2 Install a caliper mounting bracket to each spindle using the new caliper bolts Refer to Figure 10 Torque the bolts to 115 Nm 85 Ib ft ai ieee raise err aay steers Figure 10 i 1306 R19010030 AB_093009 Page 10 of 20 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING I nstall Rotor and Caliper 1 Slide the Rotor over the wheel studs and onto the hub Refer to Figure 11 Note The rotors are specific for each side of the vehicle The rotors are labeled L and R with Orange decals Installing the rotors on the wrong side of the vehicle will greatly reduce the cooling capacity of the system Hint Applying a small amount of Anti seize compound to the outer ring of the center of the hub may aid in removal of the rotor in the future Figure 11 2 Thread 3 lug nut
5. BanjoBot R A CableTies HighTemp o Z o o Jo y oda Rubber Tube Segments Z o Z O Jo Cid Bolt BrakelineBracket Cd Adel P cam o a e es Copper Crush e o O Nut Caliper Mounting o ooo i oda Washer Caliper Mounting Pg Cap Rubber i 1306 R19010030 AB_ 093009 Page 1 of 20 1 800 59 ROUSH THE ART OF PERFORMANCE ENGINEERING Packaging List for Front 6 Piston Brake Kit Part Description Part Number Qty Front 6 Piston Brake Kit with 2 Piece Rotor R19010048 14 Rotor LH front 2 piece 14 Rotor RH front 2 piece 6 Piston Caliper Front LH 6 Piston Caliper Front RH Adapter Brackets 6 Piston Caliper Front Brake Pads Installed on Calipers R19010052 Brake Dust Shields Front Brakes R19010017 Bolt Anchor Plate Mounting W710233 S439 Installation Instructions R19010030 Hardware Kit ROUSH Front Brakes R19010015 Same as a 4 Piston Hardware Kit Two Piece Rotors Qty 2 A Adapter Bracket i a Bolts Brake Caliper Brake Dust Shields 4 or 6 Piston LH amp RH Qty 2 Installation Instructions not shown 1306 R19010030 AB_ 093009 Page 2 of 20 1 800 59 ROUSH THE ART OF PERFORMANCE ENGINEERING Service Parts R19010026 4 Piston Caliper Kit R19010023 4 Piston Brake Pads R19010049 6 Piston Caliper Kit R19010052 6 Piston Brake Pads For service parts contact ROUSH Customer Service at 1 800 59 ROUSH 9 00 AM to 5 00 PM weekdays WARNING Use of any other than approved DO
6. HE BEDDING IN PROCEDURE DO NOT COME TO A COMPLETE STOP WHILE LEAVING YOUR FOOT ON THE BRAKE PEDAL AS YOU MAY IMPRINT PAD MATERI AL ONTO THE ROTOR CAUSING A VIBRATION After the first bed in cycle shown above the brakes will still not be operating at their best capacity A second or third bed in cycle is typically necessary before the brakes really start to come in A cycle is a series of stops followed by a cool down ROUSH Performance Products does not endorse exceeding the posted speed limit Note f items are missing or for any questions regarding the installation of this kit please contact ROUSH Performance toll free at 1 800 59 ROUSH Congratulations You have completed the installation of the ROUSH Performance Products Mustang Brake Upgrade Kit It is recommended that you save all parts removed from your vehicle during the installation of this kit 1306 R19010030 AB_ 093009 Page 19 of 20 1 800 59 ROUSH THE ART OF PERFORMANCE ENGINEERING WARRANTY All retail parts carry a 90 day warranty from the date of purchase This warranty covers defects in materials or workmanship and does not include i normal wear and tear environmental conditions improper installation ii road hazards misuse abuse neglect accidents collision fire theft freezing vandalism riot explosion or objects striking the vehicle iil misusing the vehicle such as driving over curbs overloading racing or using the vehicle as a s
7. ION OF IMPLIED WARRANTIES OR THEIR DURATION OR LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE EXCLUSIONS OR LIMITATIONS MAY NOT APPLY 1306 R19010030 AB_ 093009 Page 20 of 20 1 800 59 ROUSH
8. T 3 motor vehicle brake fluid will cause permanent damage to brake components and will render the brakes inoperative Failure to follow these instructions may result in personal injury WARNING Brake fluid contains polyglycol ethers and polyglycols Avoid contact with eyes Wash hands thoroughly after handling If brake fluid contacts eyes flush eyes with running water for 15 minutes Get medical attention if irritation persists If swallowed drink water and induce vomiting Get medical attention immediately Failure to follow these instructions may result in personal injury CAUTION Brake fluid is harmful to painted and plastic surfaces If brake fluid is spilled onto a painted or plastic surface immediately wash it with water CAUTION If equipped with adhesive backed brake pads do not allow the brake fluid to come in contact with the adhesive backing on the brake pads If brake fluid is spilled onto the brake pads new pads must be installed Equipment and Supplies Required e 15mm Wrench or socket 1 2 drive suggested 9 16 Wrench or socket 1 2 Flare Wrench 10mm amp 12mm Wrench or socket 11mm Wrench 1 2 socket 3 8 drive suggested 3mm amp 5mm Allen Hex wrench Torque wrench capable of 10 85 Ib ft settings Small drip tray or several rags Small funnel or suitable means of filling master cylinder reservoir Brake bleed bottle 1 Pair of jack stands ramps or other means of supporting vehicle Plastic or non ma
9. board breed screw 3 Left outboard bleed screw 4 Left inboard bleed screw 4 Bleed brakes until there is positively no air left in the system Gently tapping on the calipers with a soft non marring hammer can help to unseat trapped air 5 Torque bleed screws to 14 Nm 124 Ib in 1306 R19010030 AB_ 093009 Page 17 of 20 1 800 59 ROUSH THE ART OF PERFORMANCE ENGINEERING Test Brakes 1 Verify normal pedal travel Pedal may take several pumps to reach its normal position If travel is excessive the problem will usually be trapped air or leaks 2 With firm pressure applied to the brake pedal check all lines hoses and connections for leaks 3 Check for adequate caliper clearance to wheels Be sure to check that wheel balance weights will not interfere either Re install wheels and lower vehicle 4 Carefully test drive vehicle in a safe area at low speeds to insure all components are working correct If the vehicle operates in any way that is suspect stop the vehicle immediately and inspect repalr I mportant If anything seems unusual when operating the vehicle stop the vehicle immediately and repair as necessary Bed in Brakes FAILURE TO READ UNDERSTAND AND FOLLOW THESE PROCEDURES WILL CAUSE PERMANENT DAMAGE TO YOUR BRAKE ROTORS AND WILL KEEP THE SYSTEM FROM WORKING AT ITS FULL CAPABILITY The majority of brake system problems are due to improper installation and or bed in of the rotors and pads By reading and
10. dicular to the strut and torque the bolt to 20 Nm 177 lb in Refer to Figure 15 Figure 15 1306 R19010030 AB_ 093009 Page 13 of 20 1 800 59 ROUSH L THE ART OF PERFORMANCE ENGINEERING 3 Fasten the Brake Hose Bracket to the body using the bolt from the OEM brake hose bracket Refer to Figure 16 Torque the bolt to 20 Nm 177 Ib in Figure 16 4 Place the Adel Clamp over the Braided Brake Hose so that the offset is to the rear the car and the retainer holes are inboard when the hose is held vertical Refer to Figure 17 Hint t may be helpful to place the hose and the clamp against the bracket and mark the clamp in relation to the hose Then use pliers to squeeze the clamp around the hose and start the Brake Line Bracket Bolt through the clamp LELCTTELLLLLLLLLLA Figure 17 1306 R19010030 AB_093009 Page 14 of 20 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING 5 Bolt the hose to the hose bracket with a Brake Line Bracket Bolt Refer to Figure 18 Tighten using a 3mm driver to 2 5 Nm 22 Ib in Important The brake hose must not be twisted into place when it Is installed on the bracket If the hose is twisted it WILL NOT be able adequately move with the suspension and will possibly fail Figure 18 6 Remove the rubber cap from the brake line and connect the brake line to the brake hose Use wrenches to hold both the brake line and the brake hose ends as you tighten them Refer to Figure
11. of the pedal effort you are trying to achieve After completing the installation and driving the vehicle gently to remove the CAD plating from the rotors make a series of 10 stops from 60 to 5 10 MPH At the end of each stop immediately accelerate to 60 MPH then begin braking It is not necessary to watch the speedometer Keep your eyes on the road and approximate your speed at the end of the stop DO NOT COME TO A COMPLETE STOP WHILE LEAVING YOUR FOOT ON THE BRAKE PEDAL AS YOU MAY IMPRINT PAD MATERIAL ONTO THE ROTOR CAUSING A VIBRATION After the final stop of the cycle drive as much as possible to without using the brakes to cool off the system Ideally the brakes should be allowed to completely cool to ambient temperature before using them again There are several indicators to look for while bedding in the system On the 8 or 9 stop there should be a distinct smell from the brakes Smoke may also be evident after several stops Also on the 8 or 9 stop some friction materials will experience green fade This is a slight fading of the brakes and will stabilize but not completely go away until the brakes have cooled After the bed in cycle Is finished there will be a blue tint on the rotors and a light gray film on the rotor face The blue tint indicates that the rotor has reached the proper bed in temperature and the gray film is pad material starting to transfer onto the rotor face This is normal WHILE PERFORMING T
12. rring mallet DOT 3 or DOT 4 High Temp Brake fluid Suggested Materials e Aerosol Brake Parts Cleaner e Anti seize compound 1306 R19010030 AB_ 093009 Page 3 of 20 1 800 59 ROUSH THE ART OF PERFORMANCE ENGINEERING LIMIT OF LIABILITY STATEMENT The information contained in this publication was accurate and in effect at the time the publication was approved for printing and is subject to change without notice or liability ROUSH Performance Products RPP reserves the right to revise the information presented herein or to discontinue the production of parts described at any time SAFETY REQUIREMENTS STOP READ IMPORTANT SAFETY CAUTIONS AND WARNINGS BEFORE PROCEEDING IMPORTANT SAFETY NOTICE Appropriate disassembly assembly methods and procedures are essential to ensure the personal Safety of the individual performing the kit installation Improper installation due to the failure to correctly follow these instructions could cause personal injury or death Read each step of the installation manual carefully before starting the actual installation Always wear safety glasses for eye protection Place ignition switch in the OFF position Always apply the parking brake when working on a vehicle Block the front and rear tire surface to prevent unexpected vehicle movement If working without a lift always consult vehicle manual for correct lifting specifications 6 Operate the engine only in well ventilated areas to avoid expos
13. s onto the wheel studs and snug Check the rotor and backing plate for interference Adjust for clearance by bending the backing plate away from the rotor if where they touch 3 Remove the lug nuts from the wheel studs 1306 R19010030 AB_ 093009 Page 11 of 20 1 800 59 ROUSH THE ART OF PERFORMANCE ENGINEERING 4 Obtain the left side caliper The calipers have small orange stickers with R and L for their perspective sides Remove the Styrofoam shipping blocks from inside the calipers and slide the caliper over the rotor and the Caliper Bracket studs Refer to Figure 12 Note When installed on the correct sides the bleeder screws will be on the top side of the caliper and the crossover pipe will be on the bottom Crossover tube Figure 12 5 Loosen the top and bottom Bridge Bolts and install the 12mm washers and J et Nuts onto the caliper bracket studs Torque the Jet Nuts to 55 Nm 41 Ib ft Retighten the loosened Bridge Bolts to 12 Nm 106 lb in Refer to Figure 13 JetNuts Ala E Bridge Bolts q 5 n Figure 13 1306 R19010030 AB_093009 Page 12 of 20 1 800 59 ROUSH ROUSHI THE ART OF PERFORMANCE ENGINEERING Install Brake Hose 1 Loosely attach the Brake Hose to the caliper with the Banjo Bolt and Copper Crush Washers on each sides of the hose end as shown in Figure 14 Figure 14 2 Attach the hose mid mount to the strut using the original strut bolt Position the hose mount perpen
14. tationary power source iv altering disassembling or modifying the parts v defects caused or induced by failures breakdowns or damage by other parts components or the vehicle vi subjecting the parts to excessive moisture or water or any motor vehicle fluids e g oil anti freeze battery acid brake fluid etc vil acts of God natural disasters and other similar causes beyond the reasonable control of ROUSH or vili application of chemicals that affect the parts This Limited Warranty does not cover surface deterioration of paint trim and appearance items that result from use and or exposure to the elements such as stone chips scratches bird droppings lightning hail windstorm dings dents earthquake road salt tree sap water or flood ROUSH SHALL NOT BE LIABLE TO REIMBURSE CUSTOMER DEALER FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES RESULTING FROM THE INSTALLATION OR USE OF ANY PRODUCT SOLD THROUGH THIS CATALOG OR ARISING OUT OF ANY BREACH OF WARRANTY EXCEPT AS MAY BE STATED IN THIS CATALOG ROUSH DISCLAIMS ALL EXPRESS AND IMPLIED WARRANTIES INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN NO EVENT SHALL ROUSH S LIABILITY EXCEED THE PRICE PAID BY CUSTOMER DEALER FOR PRODUCTS SOLD REGARDLESS IF ROUSH HAS BEEN ADVISED IN ADVANCE OF ANY POTENTIAL PROBLEM OR IF A CLAIM IS BASED ON CONTRACT TORT STRICT LIABILITY PRODUCT LIABILITY OR OTHERWISE SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITAT
15. ual for jack location points Warning Never leave any vehicle supported by only a jack Always use jack stands Serious injury and or death may result 4 After securing the vehicle at a convenient height remove the front wheels Note To ensure safety the parking brake must be applied before removing the front wheels Disconnect Stock Brake Line Warning Brake fluid will damage most painted surfaces Immediately clean spilled brake fluid from any painted surface Also be sure the cap is securely installed on the master cylinder If the cap is loose or removed it is likely that more fluid will drip during brake installation 1 Remove the retaining clips that hold the ABS wheel speed sensor wiring to the brake hose from the ABS wire Refer to Figure 1 1306 R19010030 AB_ 093009 Page 5 of 20 1 800 59 ROUSH OF PERFORMANCE ENGINEERING 2 Place drip tray or several rags directly below the inboard brake line connections If the area around the brake line connection to the chassis is dirty clean it using brake cleaner or an appropriate cleaning agent Loosen the hard line fitting from the stock brake line using a 13mm flare wrench Cap the end of the line using caps provided in the hardware kit Refer to Figure 2 Warning Do not let the brake fluid drain until the master cylinder is emptied If the Master cylinder does empty the brake system will have to be bleed by a certified brake technician Line w Rubber Cap installed
16. understanding the following you will avoid the most common causes of poor brake performance and vibration Failure to read understand and follow these procedures will cause permanent damage to your new rotors Bed in or rotors and pads is critical to the optimum performance of your new brakes When bedding in new parts you are not only heat cycling the pads you a depositing a layer of material onto the rotor face If not bedded in properly an uneven layer of pad material will be deposited onto the rotor causing vibration Virtually every instance of a warped rotor is attributed to uneven pad deposition Note Bedding in pads should not be done in poor weather conditions nor on wet roads Note ROUSH brake rotors are CAD plated Plated rotors must be driven with gentle braking until the CAD plating is warn off BEFORE starting the bed in procedure Do not use brakes aggressively until the plating is worn off typically after several miles of driving 1306 R19010030 AB_ 093009 Page 18 of 20 1 800 59 ROUSH THE ART OF PERFORMANCE ENGINEERING Typically a heavy braking street driver will experience approximately 1 to 1 1G s of deceleration At this rate the ABS will be activated on such equipped vehicles A moderate braking effort is needed to properly bed in rotors and pads If ABS intervention or lock up were represented as 100 brake effort a stopping force of 70 80 just short of ABS intervention or lock up is a general estimate
17. ure to carbon monoxide 7 Do not smoke or use flammable items near or around the fuel system 8 Use chemicals and cleaners in well ventilated areas 9 Batteries produce explosive gases which can cause personal injury Therefore do not allow flames sparks or flammable substances to come near the battery 10 Keeps hands and any other objects away from the radiator fan blades 11 Keep yourself and your clothing away from moving parts when the engine is running 12 Do not wear loose clothing or jewelry that can get caught in rotating parts or scratch Surface finishes 13 Allow the engine cooling system brakes and exhaust to cool before working ona vehicle ee eS WORK SAFELY Perform this installation on a good clean level surface for maximum safety and with the engine turned off 1306 R19010030 AB_ 093009 Page 4 of 20 1 800 59 ROUSH ROUSH THE ART OF PERFORMANCE ENGINEERING Disassembly Note All photographs show the left hand side installation unless noted Right hand side is similar All steps must be repeated for the right hand side Raise Vehicle Remove Wheels 1 Locate a level stable and clean surface suitable for supporting the vehicle on jack stands 2 Apply parking brake and break loose front lug nuts 3 Refer to the Owner s Manual to identify the correct location of the jack for raising the vehicle Jack up the vehicle and secure it on a pair of jack stands again referring to the Owner s Man
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