Tools You'll Need:
* Jack and jack stands (essential for safety)
* Wheel chocks
* Lug wrench
* Socket set (metric) – including sizes for lug nuts, caliper bolts, and parking brake cable adjuster
* Wrench set (metric)
* C-clamp or brake caliper compression tool
* Brake cleaner
* Wire brush
* Pliers
* New rear brake pads
* New rear brake rotors (if needed – inspect carefully)
* Wheel cylinder rebuild kit (if needed – inspect for leaks)
* Anti-seize lubricant
* Grease
* Safety glasses
* Gloves
Steps:
1. Safety First: Park on a level surface, engage the parking brake, and chock the front wheels. Use jack stands to securely lift the rear of the vehicle after jacking it up. Never work under a vehicle supported only by a jack.
2. Remove the Wheel: Loosen the lug nuts before jacking up the vehicle. Remove the wheel and set it aside.
3. Inspect the Brakes: Carefully inspect the brake pads, rotors, and wheel cylinder for wear, damage, or leaks. Replace any worn or damaged components.
4. Release the Parking Brake: Locate the parking brake cable adjuster. You'll need to loosen this to allow the brake shoes to retract. The exact method varies slightly depending on the year and model. Consult your repair manual.
5. Remove the Caliper: Locate the caliper mounting bolts. Usually, there are two. Unscrew them and carefully remove the caliper. Support the caliper with a bungee cord or wire to prevent it from hanging by the brake line.
6. Compress the Piston: Use a C-clamp or brake caliper compression tool to push the piston back into the caliper. This will create space for the new, thicker brake pads. Be careful not to damage the piston seal.
7. Remove the Old Brake Pads: The old brake pads should now be easily removable.
8. Remove and Inspect Rotors (if necessary): If replacing rotors, remove them now. They're typically held on by a few bolts.
9. Install New Rotors (if necessary): Install the new rotors.
10. Install New Brake Pads: Install the new brake pads, ensuring they slide smoothly in the caliper bracket.
11. Reinstall the Caliper: Carefully reinstall the caliper and tighten the mounting bolts to the manufacturer's specified torque.
12. Reinstall the Wheel: Install the wheel and tighten the lug nuts.
13. Adjust Parking Brake: After reinstalling the caliper, you may need to readjust the parking brake cable adjuster. Refer to your repair manual for the correct procedure. This is often done by turning a small nut on the cable.
14. Lower the Vehicle: Carefully lower the vehicle to the ground.
15. Test the Brakes: Before driving, pump the brake pedal several times to ensure proper function. Test drive carefully and immediately report any issues.
Important Considerations:
* Brake fluid: Brake fluid is highly corrosive and can damage paint. Clean up any spills immediately. You may need to bleed the brakes if you've worked on the hydraulic system.
* Repair Manual: A repair manual specific to your year and model of Ford Freestar is highly recommended. It will provide detailed instructions, torque specifications, and diagrams. You can find these online or at auto parts stores.
* Wheel Cylinder: If you find leaks or damage to the wheel cylinder, you will need to replace or rebuild it. This is a more complex task.
This process is a summary and doesn't cover every possible scenario. If you're not comfortable working on your brakes, it's best to take your vehicle to a qualified mechanic. Incorrectly installed brakes are a serious safety hazard.
