Tools You'll Likely Need:
* Jack and jack stands (crucial for safety!)
* Lug wrench
* Wheel chocks
* Socket wrench with appropriate sockets (likely 14mm or 17mm for caliper bolts, and others for rotor retaining hardware if applicable)
* C-clamp or caliper compression tool
* Wire or bungee cord to secure the caliper
* Penetrating oil (like PB Blaster)
* Torque wrench
* Clean rags or shop towels
Procedure:
1. Safety First: Park on a level surface, engage the parking brake, and chock the rear wheels. Use jack stands to securely lift the front of the vehicle after jacking it up. Never work under a vehicle supported only by a jack.
2. Remove the Wheel: Remove the lug nuts and carefully take off the wheel.
3. Expose the Caliper: You should now see the brake caliper clamping onto the rotor.
4. Compress the Caliper: This is the most important and potentially tricky step. You'll need to compress the caliper piston back into its bore to create enough space for the rotor to be removed. Use a C-clamp or caliper compression tool to carefully compress the piston. Be aware that brake fluid will be displaced as you compress the piston. Have a clean rag ready to absorb the fluid and avoid getting it on your skin or painted surfaces. Some pistons may rotate as they compress.
5. Secure the Caliper: Once the piston is sufficiently compressed, you can usually just hang the caliper out of the way using a wire or bungee cord attached to something secure nearby. Don't let the caliper hang by the brake line alone.
6. Remove the Rotor: There might be a retaining clip or bolt holding the rotor to the hub. If present, remove this. Then, carefully slide or pull the rotor off the hub. Sometimes, they are stubborn and might require a gentle tap with a rubber mallet (carefully aimed to avoid damaging the rotor or hub).
7. Clean and Inspect: Clean the hub mounting surface of any rust or debris. Inspect the rotor for wear and tear; replace if necessary.
8. Install the New Rotor (if replacing): Carefully slide the new rotor onto the hub. Replace the retaining clip or bolt (if applicable) and ensure it's securely fastened.
9. Reinstall the Caliper: Carefully reattach the caliper to the caliper bracket. Be sure to tighten the caliper bolts to the manufacturer's specified torque.
10. Reinstall the Wheel: Replace the wheel and tighten the lug nuts in a star pattern to the manufacturer's specified torque.
11. Lower the Vehicle: Carefully lower the vehicle from the jack stands. Double-check the lug nuts are tight before driving.
12. Test the Brakes: After reinstalling everything, gently pump the brake pedal a few times to ensure the brakes are working correctly before driving. A test drive is recommended but do so cautiously until you're confident in the braking performance.
Important Notes:
* Brake fluid is corrosive and harmful. Wear appropriate safety glasses and gloves.
* If you're uncomfortable with any part of this process, it's best to take your Expedition to a qualified mechanic. Improper brake repair can be dangerous.
* Always consult your vehicle's repair manual for specific instructions and torque specifications. This guide is a general overview.
This detailed explanation should help. Remember safety first! If you have any doubts, seek professional help.
