Here's a general outline. Always consult a repair manual specific to your 2002 Ford Explorer for detailed instructions and torque specifications. These instructions are general and may vary slightly depending on your specific model (Sport Trac, etc.).
Tools You'll Need:
* Jack and jack stands: Essential for safety. Never work under a car supported only by a jack.
* Wheel chocks: To prevent the vehicle from rolling.
* Lug wrench: To remove the wheel.
* Socket wrench set: With the correct sizes for lug nuts, caliper bolts, and rotor retaining hardware (if any).
* C-clamp or caliper compression tool: To compress the brake caliper piston.
* Wrench or socket to turn the caliper bracket bolts: These can be stubborn.
* Penetrating oil (PB Blaster, etc.): To help loosen rusted bolts.
* Torque wrench: Absolutely crucial for tightening bolts to the correct specifications.
* Clean rags or shop towels: To keep things clean.
* Wire brush or sandpaper: To clean the hub mating surface.
* New brake rotors: Make sure you get the correct ones for your vehicle.
* New brake pads (recommended): Replacing the pads at the same time is best practice, even if they aren't completely worn.
Steps:
1. Safety First: Engage the parking brake, chock the wheels, and jack up the vehicle securely on jack stands. Remove the wheel.
2. Remove the Caliper:
* Use the C-clamp or compression tool to push the caliper piston back into the caliper. This creates the space needed to remove the rotor. Be careful not to damage the piston seal.
* Use the appropriate wrench or socket to remove the caliper mounting bolts. These can be very tight and may require penetrating oil. Support the caliper with a bungee cord or wire to keep it from dangling.
3. Remove the Rotor:
* There might be a retaining screw or clip on the back of the rotor. Remove it if present.
* The rotor should now slide off the hub. If it's stuck, gently tap it with a rubber mallet or hammer (through a block of wood to avoid damaging the rotor). Never hit it directly with a hammer.
4. Clean the Hub: Use a wire brush or sandpaper to thoroughly clean the hub mating surface where the rotor sits. Any rust or debris will prevent proper contact.
5. Install the New Rotor: Slide the new rotor onto the hub. Make sure it seats properly.
6. Install the Caliper: Reinstall the caliper and its bolts, tightening them to the manufacturer's specified torque.
7. Reinstall the Wheel: Tighten the lug nuts snugly but don't fully tighten them yet.
8. Lower the Vehicle: Lower the vehicle to the ground.
9. Torque Lug Nuts: Tighten the lug nuts to the manufacturer's specified torque using a torque wrench.
10. Repeat for other wheels: Repeat steps 1-9 for each wheel that needs a new rotor.
11. Test Brakes: After installing new rotors and pads, carefully test the brakes in a safe, open area to ensure they're functioning properly. Pump the brake pedal several times to build pressure. If the pedal feels spongy or the brakes are weak, you may have air in the brake lines and will need to bleed the brakes. This is a more advanced procedure.
Important Considerations:
* Rust: On older vehicles, bolts can be extremely rusted and difficult to remove. Use penetrating oil generously and allow it to soak in for several hours before attempting to remove them. You may need to use heat (carefully!) to help break them loose. Broken bolts can significantly complicate the repair.
* Brake Fluid: When compressing the caliper piston, brake fluid will be displaced. Be prepared to catch it and dispose of it properly. Brake fluid is corrosive.
* Torque Specifications: Using a torque wrench and adhering to the manufacturer's torque specifications is essential for safe and proper operation of your brakes. Incorrect torque can lead to loose or broken components.
Again, this is a general outline. Always consult a repair manual specific to your 2002 Ford Explorer before attempting this repair. If you are uncomfortable with any step, do not hesitate to seek professional help. Brake failure can be catastrophic.
