Here's a general outline. Consult a repair manual specific to your 2003 Ford Windstar for detailed instructions, torque specifications, and diagrams. This information is for guidance only and may not cover every variation.
Tools You'll Need:
* Jack and jack stands (essential for safety!)
* Lug wrench
* Wheel chocks
* Socket wrench set (metric)
* Torque wrench (essential for proper brake system safety)
* C-clamp or brake caliper compressor tool
* Pliers
* Wire brush
* Brake cleaner
* New brake shoes, springs, clips, and hardware kit (Always replace these parts as a set)
* Possibly a drum-type brake spring tool (depending on the design)
Procedure:
1. Safety First: Park on a level surface, engage the parking brake, and chock the front wheels. Raise the vehicle using the jack and securely support it on jack stands. Never work under a vehicle supported only by a jack.
2. Remove the Wheel: Remove the lug nuts and take off the wheel.
3. Inspect the Drum: The rear brakes on a Windstar are likely drum brakes. Carefully inspect the brake drum for any damage or excessive wear. If the drum is severely rusted or pitted, it may need replacement.
4. Remove the Drum: This can sometimes be stubborn. Gently tap the drum around its circumference with a rubber mallet to loosen it. Sometimes a few light taps with a pry bar between the drum and backing plate may help, but be extremely careful not to damage the backing plate or drum.
5. Inspect the Brake Shoes: Once the drum is off, inspect the brake shoes for wear. Measure the lining thickness to determine if replacement is necessary. Generally, if the lining is worn below the minimum thickness specified in your repair manual, they need replacing.
6. Remove the Old Brake Shoes: Carefully remove the old brake shoes, paying close attention to the springs, clips, and adjuster mechanism. Take pictures or make detailed notes of how everything is assembled. This will be crucial during reassembly. Many parts are small and easily misplaced.
7. Install the New Brake Shoes: Install the new brake shoes, springs, and clips according to the arrangement you observed or documented. Ensure everything is correctly seated and secure. This is often the most challenging part, due to the spring tension and small parts. A brake spring tool might be needed to help with this.
8. Adjust the Brake Shoes: Adjust the self-adjusters on the backing plate as per the instructions in your repair manual. This is crucial for proper brake function.
9. Reinstall the Drum: Carefully slide the brake drum back onto the backing plate. It should slide on relatively easily.
10. Reinstall the Wheel: Install the wheel and tighten the lug nuts in a star pattern (opposite nuts).
11. Lower the Vehicle: Lower the vehicle using the jack. Then, fully tighten the lug nuts with the lug wrench.
12. Check for Leaks: Check for any brake fluid leaks around the wheel cylinder.
13. Pump the Brakes: Pump the brake pedal several times to restore pressure in the system. Check your brake fluid level and top off if necessary.
14. Test Drive: Carefully test the brakes. Make a few stops from low speed. If anything feels amiss (spongy pedal, pulling to one side), have a mechanic check the brakes immediately.
Important Considerations:
* Safety: Brake work requires careful attention to detail. A mistake can be very dangerous.
* Repair Manual: Always consult a repair manual specific to your vehicle.
* Torque Specifications: Use a torque wrench to tighten bolts to the manufacturer's specified torque.
* Brake Fluid: Be aware that brake fluid is corrosive and harmful to your skin and paint.
This is a simplified overview. Again, consult a repair manual specific to your 2003 Ford Windstar for precise instructions and safety precautions. If you're not comfortable performing this repair, it's best to take your vehicle to a qualified mechanic.
