This outlines the general steps; specifics might vary slightly depending on your exact model and brake system components. Always consult a repair manual specific to your 1997 Mercury Villager for detailed instructions and torque specifications.
Tools You'll Need:
* Jack and jack stands (crucial for safety!)
* Lug wrench
* Wheel chocks
* Socket wrench set (metric)
* Brake caliper wrench (C-clamp style or specialized tool)
* Pliers
* Screwdrivers (Phillips and flathead)
* Wire brush
* Brake cleaner
* New brake pads
* New rotors (likely needed, as worn pads often damage rotors)
* Possibly new calipers (inspect them carefully; if they're seized or leaking, replace them)
* Possibly new brake lines (inspect for leaks or damage)
* Torque wrench (essential for proper tightening)
* Gloves
* Safety glasses
Steps (General Outline - Consult Your Repair Manual for Precise Details):
1. Safety First: Park on a level surface, engage the parking brake, chock the wheels, and use jack stands to securely lift the vehicle. Never work under a vehicle supported only by a jack.
2. Remove the Wheel: Loosen the lug nuts slightly before lifting the vehicle. Once lifted and supported by jack stands, remove the lug nuts completely and take off the wheel.
3. Inspect the Brakes: Carefully examine the brake pads, rotors, calipers, and brake lines for wear, damage, or leaks. Replace anything that's worn, damaged, or leaking.
4. Remove the Caliper: This usually involves compressing the caliper piston (using a C-clamp or specialized tool) to make room for the new, thicker pads. Be careful not to damage the piston seal or the caliper itself. You may need to remove a retaining pin or bolt securing the caliper to the bracket.
5. Remove the Brake Pads: The old brake pads should slide out relatively easily after the caliper is removed.
6. Remove and Replace the Rotors (if necessary): If the rotors are scored or warped, replace them. They are usually held on by bolts.
7. Install New Rotors (if necessary): Install the new rotors, ensuring they are properly seated.
8. Install New Brake Pads: Insert the new brake pads into the caliper bracket.
9. Reinstall the Caliper: Mount the caliper back onto the bracket, ensuring it's properly aligned and secured.
10. Reinstall the Wheel: Put the wheel back on and tighten the lug nuts finger-tight.
11. Lower the Vehicle: Carefully lower the vehicle using the jack.
12. Torque the Lug Nuts: Tighten the lug nuts to the manufacturer's specified torque using a torque wrench. This is crucial to prevent wheel detachment.
13. Pump the Brakes: Pump the brake pedal several times to ensure the brakes are working properly.
14. Bleed the Brakes (Important): After replacing brake components, you'll likely need to bleed the brakes to remove air from the brake lines. This is a critical step to ensure proper braking performance. This often requires two people and a bleeding tool.
15. Test the Brakes: Test the brakes thoroughly in a safe, controlled environment before driving the vehicle.
Disclaimer: This is a general guide. Improper brake work can be dangerous. If you're not comfortable performing this task yourself, consult a professional mechanic. Always refer to a repair manual specific to your vehicle for detailed instructions and safety precautions. Improperly installed brakes can lead to accidents.
