Tools You'll Need:
* Jack and jack stands
* Lug wrench
* Wheel chocks
* Socket wrench with appropriate sockets (likely 1/2" drive)
* Possibly a torque wrench (for reassembly)
* Caliper piston compressor tool (crucial)
* Hammer (possibly a rubber mallet)
* Penetrating lubricant (like PB Blaster)
Procedure:
1. Safety First: Park on a level surface, engage the parking brake, and chock the rear wheels. Raise the front of the Explorer using the jack and securely place it on jack stands. Remove the wheel.
2. Caliper Removal: Locate the caliper mounting bolts. These are usually on the back of the caliper. Spray them with penetrating lubricant and let it sit for a few minutes. Unscrew the bolts and carefully remove the caliper. Do not disconnect the brake line. You may need to carefully support the caliper with a bungee cord or wire to keep it from hanging by the brake line.
3. Caliper Piston Compression: This is the most important and potentially tricky step. The brake caliper piston needs to be compressed to allow the rotor to slide off. Use a caliper piston compressor tool. This tool prevents damage to the piston and seals. Slowly compress the piston until the caliper can be easily removed from the rotor. If you don't have a compressor tool, you can try using C-clamps, but this is risky and can damage the seals.
4. Rotor Removal: Now, the rotor should be free to slide off the wheel studs. If it's stuck, gently tap it from the back with a rubber mallet. Avoid hitting the wheel studs. If it’s really stuck, use a pry bar carefully to separate the rotor from the hub. Never damage the wheel hub itself.
5. Installation (Reverse Order): To reinstall, simply reverse the steps above. Make sure to lubricate the caliper mounting bolts. Be sure to properly torque the bolts to specifications (consult your repair manual). When reinstalling the wheels, torque the lug nuts to the manufacturer's specification.
Important Considerations:
* Rust: If your vehicle is older, rust can make this job more difficult. Use penetrating lubricant liberally and allow ample time for it to work.
* Repair Manual: Consult a repair manual specific to your 1993 Ford Explorer 4WD. It will provide detailed diagrams, torque specifications, and other crucial information.
* Brake Fluid: If you have to significantly compress the brake caliper piston, you may need to open the bleeder valve on the caliper to prevent brake fluid from overflowing and potentially causing damage. Have a catch container ready. Once the new rotor is installed, you may need to bleed your brakes, again consulting your repair manual for proper procedure.
Disclaimer: This is a general guide. Improperly performing these steps could lead to brake failure and injury. If you are not comfortable performing this repair yourself, take your vehicle to a qualified mechanic.
