This guide provides a general overview. Always consult your owner's manual for specific procedures and torque specifications for your vehicle. Variations exist depending on whether you have rear drum brakes or disc brakes. Most 2003 Expeditions had disc brakes in the front and drum brakes in the rear.
Tools You'll Need (at minimum):
* Jack and jack stands: Essential for safety. Never work under a vehicle supported only by a jack.
* Wheel chocks: To prevent the vehicle from rolling.
* Lug wrench: To remove the wheels.
* Socket wrench set: With various sizes, including metric.
* Wrench set: For various nuts and bolts.
* C-clamp (for rear drums): To compress the wheel cylinder.
* Brake caliper compression tool (for front discs): To retract the brake caliper pistons.
* Pliers: For various tasks.
* Screwdrivers (Phillips and flathead): Potentially needed.
* Brake cleaner: To clean brake parts thoroughly.
* New brake pads (front and rear): Get the correct pads for your vehicle.
* New rotors (front, if needed): Check for wear and scoring. Replacement is often needed with new pads.
* New brake shoes and wheel cylinders (rear drums, if needed): Check for wear and leaks.
* Grease: For lubrication of caliper pins and other parts.
* Gloves: Protect your hands.
* Safety glasses: Protect your eyes.
Procedure (General Outline - Consult your manual for specifics):
1. Front Disc Brakes (If applicable):
* Safety First: Park on a level surface, engage the parking brake, and use jack stands.
* Remove Wheel: Loosen lug nuts before jacking, then remove wheel.
* Remove Caliper: Remove caliper bolts (often 14mm or 15mm) and carefully support the caliper with a wire or bungee cord to prevent it from hanging by the brake line.
* Compress Caliper Piston: Use a caliper compression tool to push the piston back into the caliper. This creates space for the new, thicker pads.
* Remove Brake Pads: Remove the old brake pads.
* Inspect Rotor: Check the rotor for wear and scoring. Replace if necessary.
* Install New Pads: Install the new brake pads.
* Reinstall Caliper: Carefully reinstall the caliper, ensuring it's properly seated.
* Reinstall Wheel: Reinstall the wheel and tighten lug nuts.
2. Rear Drum Brakes (If applicable):
* Safety First: Same as above.
* Remove Wheel: Same as above.
* Remove Drum: Remove the brake drum (it might be stuck; tapping gently around the circumference may help).
* Remove Shoes: Remove the old brake shoes.
* Inspect Wheel Cylinder: Check the wheel cylinder for leaks. Replace if necessary.
* Compress Wheel Cylinder: Use a C-clamp to compress the wheel cylinder pistons.
* Install New Shoes: Install the new brake shoes. Ensure the automatic adjusters are working properly.
* Reinstall Drum: Reinstall the brake drum. It should fit snugly.
* Reinstall Wheel: Same as above.
3. Bleed Brakes (Crucial):
After replacing any brake components, you must bleed the brakes to remove air from the brake lines. This is a two-person job, requiring one person to pump the brake pedal and another to open and close the bleeder valves on each caliper/wheel cylinder. Refer to your owner's manual for the correct bleeding order.
Important Considerations:
* Torque Specifications: Use a torque wrench to tighten all bolts to the manufacturer's specifications. Over-tightening can damage components.
* Brake Fluid: If you're working on the brake system, you may need to add brake fluid. Use the correct type of brake fluid recommended in your owner's manual.
* Safety: Brake work is critical for safety. If you're unsure about any step, don't hesitate to seek professional help. Improperly installed brakes can be extremely dangerous.
This is a simplified guide. Refer to a repair manual specific to your 2003 Ford Expedition for detailed instructions, diagrams, and torque specifications. You can find these manuals online or at auto parts stores. Failing to follow correct procedures could lead to brake failure and serious injury.
