Rear Disk Conversion

The Ford Mondeo hit our roads in 1993, and has consistently been a sales success. Now on its 4th incarnation, it remains a drivers favourite.
For more information, visit the Ford Mondeo forum on TalkFord.com, the definitive resource site covering all Fords from the present day to the 1970's.

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Overview Guide
Ford Model:	Mondeo
Petrol/Diesel:	???
Estimated Cost:	???
Difficulty?	???
How long does this take?	???

Rear Disk Conversion

Method

First loosen the bolts on the rear wheels do not undo them just crack them then find the jacking points and jack up one side. I started with the driver side.

Now remove wheel. You will need to take the drum apart to remove the handbrake cable. Use a rubber mallet to loosen the drum from the hub, remove the drum.

Remove the springs using a pair of pliers that hold the shoes in place. Remove the shoes and use a 13mm ring spanner to remove the handbrake cable from the back plate.

Locate the brake pipe and separate it from the body.

Now locate the 4 bolts that hold the ankle on they are shown in the photo above. Once they are removed the ankle should come out. It may take some persuasion.

Now remove the anti roll bars suspension links from the suspension arm.

Now place the disc ankle on the strut and do the reverse of removing the drum but ignore the handbrake cable for now.

Don’t forget to bleed the brakes when both sides are done.

Now you have to add the handbrake cable. I have replaced the two secondary cables on mine, the drum ones don’t fit anyway and I don’t want to trust my car to some that have been in a scrap yard.

Lower exhaust and remove the shield under (over) centre box. You will find the secondary cables and the cable going to the hand brake shown in picture above.

Remove them and replace them with the new cables and connect them to the callipers. If you have problems with a lack of length then try pumping the foot brake a couple of times if not you will need to locate the auto adjuster in the hand brake and wind it back with a screw driver, you can access this by removing the centre console in the cockpit. Then replace shield and reattach exhaust. Release jack then you’re done.

You may find it easier if you jack you car from the centre where the suspension connects to and then once the when the suspension it back together (both callipers have been replaced) and you are going to under to do the hand brake. While lifted by the jack in the centre place a jack under each of the larger of the suspension arm an axle stand then remove jack.

Note to those with Estates

You only need for this project the rear callipers, Discs, Pads and hand brake cable. You don’t need the suspension ankle as your ankle is the same on both disc and drum brakes. Follow the how to above to the point that the hand brake cable is removed then follow the following instructions.

Unbolt the back plate from the suspension ankle and locate the two points that the calliper connects to.

Put the disc on and place the calliper in to the position and tighten bolts

Connect up the brake pipe.

Now place the disc ankle on the strut and do the reverse of removing the drum but ignore the handbrake cable for now.

Don’t forget to bleed the brakes when both sides are done.

Now follow the points about setting up the handbrake cable

Enjoy rear disc!!