Disclaimer: This is a general guide. Specific procedures may vary slightly depending on the exact trim level and condition of your Villager. Always consult a repair manual specific to your vehicle year and model for the most accurate instructions and torque specifications.
Tools you'll likely need:
* Jack and jack stands (Safety First! Never work under a vehicle supported only by a jack.)
* Lug wrench
* Wheel chocks
* Socket wrench set (metric) with various extensions and ratchets
* Brake caliper piston compressor tool (essential)
* C-clamp (can be used as a substitute for a compressor tool, but less convenient and potentially damaging)
* Pliers
* Wire brush
* Brake cleaner
* New brake pads
* New rotors (highly recommended, but not always strictly necessary if the old ones are in good condition – check for scoring, excessive wear, or warping)
* Grease
* Torque wrench (crucial for safety)
* Safety glasses and gloves
Steps:
1. Safety First: Park on a level surface, engage the parking brake, chock the front wheels, and jack up the rear of the vehicle securely. Support the vehicle on jack stands before proceeding.
2. Remove the Wheel: Remove the lug nuts and take off the wheel.
3. Remove the Caliper: Locate the caliper bolts securing the caliper to the caliper bracket. These are usually on the back of the caliper. Unscrew them and carefully remove the caliper. Be prepared for some brake fluid to leak – it's a good idea to have some rags handy. You may need to gently pry the caliper away from the rotor.
4. Compress the Caliper Piston: This is crucial. Use the piston compressor tool to push the caliper piston back into the caliper housing. This creates the space needed for the new, thicker brake pads. Do not use excessive force. If you're using a C-clamp, be very careful not to damage the piston seal.
5. Remove the Old Brake Pads: The old brake pads should now be easily removable. You may need to use pliers to gently pry them out.
6. Inspect the Rotors: Carefully inspect the rotors for scoring, grooves, or excessive wear. If they are damaged, replace them.
7. Install New Brake Pads: Install the new brake pads into the caliper bracket.
8. Install the Caliper: Reinstall the caliper onto the bracket, securing it with the bolts.
9. Reinstall the Wheel: Put the wheel back on and tighten the lug nuts. Do not fully tighten them yet.
10. Repeat Steps 3-9 on the Other Side: Repeat the process for the other rear wheel.
11. Lower the Vehicle: Carefully lower the vehicle to the ground using the jack.
12. Tighten Lug Nuts: Tighten the lug nuts to the manufacturer's specified torque (consult your repair manual).
13. Pump the Brakes: Pump the brake pedal several times to build up pressure in the brake system.
14. Check for Leaks: Inspect the brake calipers and lines for any leaks.
15. Test Drive: Take a short test drive to ensure the brakes are functioning correctly. If you feel anything unusual, stop immediately and re-check your work.
Important Considerations:
* Brake Fluid: You may need to bleed the brakes after replacing the pads and potentially the rotors to remove any air that might have entered the system. This is a more advanced procedure requiring a helper and a brake bleeder kit. If you're not familiar with this, take it to a professional.
* Parking Brake: Some vehicles have a separate mechanism for the parking brake integrated into the rear brake system. Be aware of this and how it functions when you remove and reinstall the brake calipers. A repair manual will provide specific details.
* Parts: Always ensure you're using parts that are specifically designed for your 1999 Mercury Villager.
This guide provides a general overview. Again, always refer to a repair manual specific to your vehicle for detailed instructions and safety precautions. Improper brake repair can be extremely dangerous. If you are not comfortable performing this repair yourself, it's best to take your vehicle to a qualified mechanic.
