Here's a general outline of the process. Specific details may vary slightly depending on your van's exact configuration (e.g., disc or drum brakes, ABS). Always consult a repair manual specific to your 1999 Ford E-150 for detailed instructions and torque specifications. Your owner's manual may also have some helpful information.
1. Safety First:
* Park on a level surface and engage the parking brake firmly.
* Chock the rear wheels.
* Wear safety glasses and gloves.
2. Gather Tools and Parts:
You'll need the following (exact parts may vary):
* New brake pads: Make sure you get the correct ones for your E-150.
* New rotors (if necessary): Inspect your existing rotors for scoring, grooves, or excessive wear. If they're damaged, replace them.
* Brake caliper rebuild kit (if necessary): If your calipers are leaking or sticking, you'll need a rebuild kit. Sometimes replacing calipers is easier than rebuilding them.
* Wheel wrench.
* Jack and jack stands (never work under a vehicle supported only by a jack).
* Socket wrench set (metric).
* C-clamp or caliper compression tool.
* Wrench for brake caliper bolts.
* Torque wrench.
* Penetrating oil (PB Blaster or similar).
* Clean rags.
* Brake cleaner.
* Repair manual specific to your 1999 Ford E-150.
3. Procedure (Disc Brakes - Most likely on a 1999 E-150):
* Raise and support the vehicle: Safely jack up the front of the van and secure it on jack stands.
* Remove the wheel: Use the wheel wrench to remove the lug nuts and take off the wheel.
* Compress the caliper piston: Use a C-clamp or caliper compression tool to push the caliper piston back into the caliper. This creates space for the new, thicker brake pads. Be careful not to damage the piston seal.
* Remove the brake pads: Typically, there are pins or clips holding the brake pads in place. Remove these and carefully take out the old pads.
* Inspect the caliper: Check the caliper for leaks, damage, or sticking. If necessary, replace it or rebuild it using the rebuild kit.
* Install new brake pads: Carefully insert the new brake pads into their slots.
* Reinstall the caliper: Put the caliper back in place and secure it with the caliper bolts. Torque these bolts to the specifications in your repair manual.
* Install the wheel: Replace the wheel and tighten the lug nuts. Do not overtighten.
* Lower the vehicle: Carefully lower the van from the jack stands.
* Test the brakes: After installing both sides, pump the brake pedal several times to build up pressure. Test the brakes in a safe, controlled area (empty parking lot) at low speeds. The brakes should feel firm and responsive. If they feel spongy or ineffective, there might be an issue requiring further investigation.
4. Procedure (Drum Brakes - Less likely, but possible):
If you have drum brakes, the process is different. You'll need to remove the brake drum, then the shoes, springs, and adjusters. Installation is the reverse of removal. Again, a repair manual is essential.
Important Notes:
* Bleeding the brakes: After installing new brake components, you may need to bleed the brakes to remove any air bubbles in the brake lines. This is another crucial step to ensure proper brake function. Refer to your repair manual for the correct bleeding procedure.
* Torque Specifications: Always use a torque wrench and follow the torque specifications in your repair manual. Over-tightening can damage components.
* ABS Systems: If your van has an Anti-lock Braking System (ABS), working on the brakes can be more complex. You might need special tools and knowledge to avoid damaging the ABS system.
This is a simplified overview. Refer to a repair manual for your specific vehicle model and year before attempting this repair. If you're not comfortable with any part of this process, take your van to a qualified mechanic. Brake failure is extremely dangerous.
