Here's a general overview of the process. Always consult a repair manual specific to your 1993 Ford Explorer for detailed instructions and torque specifications. This information is for guidance only and may not cover all variations.
Tools You'll Need:
* Wrench set (metric): Various sizes will be needed for bolts and lines.
* Socket set (metric): Similar to wrenches, various sizes are needed.
* Brake line wrench: To avoid damaging the brake lines.
* C-clamp or vice grips: To compress the master cylinder pistons.
* New master cylinder: Ensure it's the correct one for your vehicle.
* Brake fluid: DOT 3 or DOT 4, as specified for your vehicle.
* Catch pan: To collect old brake fluid.
* Funnel: To add new brake fluid.
* Clean rags or shop towels: For cleaning up spills.
* Gloves: Protect your hands from brake fluid.
* Safety glasses: To protect your eyes from brake fluid splashes.
* Bleeder wrench: For bleeding the brakes after installation.
* A helper: Bleeding brakes is often easier with two people.
Procedure (General Steps):
1. Safety First: Disconnect the negative battery terminal to prevent electrical shorts.
2. Fluid and Pressure Release: Open the brake fluid reservoir and carefully remove as much brake fluid as possible. This minimizes the mess when you remove the master cylinder.
3. Disconnect Brake Lines: Using a brake line wrench, carefully loosen and remove the brake lines from the master cylinder. Have a catch pan ready to collect any remaining brake fluid.
4. Disconnect the Master Cylinder: This usually involves removing several bolts holding the master cylinder to the booster. Take note of the order and position of components for reassembly.
5. Remove the Master Cylinder: Carefully remove the master cylinder from the booster.
6. Install the New Master Cylinder: Before installing the new master cylinder, make sure the piston is fully compressed using a C-clamp or vice grips. Carefully align the new master cylinder and bolt it to the booster.
7. Reconnect Brake Lines: Carefully reconnect the brake lines to the new master cylinder. Make sure they are tightened securely with a brake line wrench.
8. Fill Brake Fluid Reservoir: Fill the brake fluid reservoir with the correct type of brake fluid to the appropriate level.
9. Bleed the Brakes: This is crucial to remove any air that may have entered the system during the replacement. Use a bleeder wrench and a helper to bleed the brakes at each wheel, starting with the furthest wheel from the master cylinder (rear passenger side, then rear driver side, then front passenger side, then front driver side, though consult your manual for specifics). This ensures all air is expelled. Continue bleeding until firm, consistent pressure is felt at the brake pedal.
10. Check Fluid Level: After bleeding, check the brake fluid reservoir and add more if needed.
11. Test the Brakes: Before driving, carefully test the brakes in a safe, controlled environment. If the brakes feel spongy or weak, there's likely still air in the system and you need to re-bleed.
Important Considerations:
* Brake fluid is corrosive. Clean up any spills immediately.
* Never work on the brake system alone. Have a helper available to assist.
* Always use the correct type of brake fluid.
* Proper bleeding is essential for safe brake operation.
* If you're unsure about any step, consult a professional mechanic.
This is a simplified overview. A detailed repair manual specific to your 1993 Ford Explorer is absolutely necessary for a safe and successful repair. Incorrect installation can lead to brake failure, which can have severe consequences. Prioritize safety and don't hesitate to seek professional help if needed.
