Tools You'll Need:
* Jack and jack stands: Absolutely essential for safety. Never work under a vehicle supported only by a jack.
* Wheel chocks: To prevent the vehicle from rolling.
* Lug wrench: To remove the wheels.
* Socket wrench set: Including metric sizes. You'll likely need sockets for caliper bolts, and potentially others depending on your caliper design.
* C-clamp or caliper compression tool: To compress the caliper piston. A C-clamp works, but a dedicated tool is safer and easier.
* Wrench to turn caliper slide pins (if necessary): These pins may need lubrication and turning to allow the caliper to slide properly.
* Penetrating oil (like PB Blaster): To help loosen any rusted or seized bolts.
* Brake cleaner: To clean the caliper and rotor surfaces.
* New brake pads: Make sure you get the correct pads for your vehicle's model and year. Check your owner's manual or a parts store for the correct part number.
* Gloves: To keep your hands clean.
* Safety glasses: To protect your eyes.
* Torque wrench (optional but recommended): To tighten bolts to the manufacturer's specified torque.
Steps:
1. Safety First: Park on a level surface, engage the parking brake, and chock the wheels. Jack up the vehicle and securely support it on jack stands.
2. Remove the Wheel: Remove the lug nuts and carefully take off the wheel.
3. Expose the Caliper: You should now see the brake caliper assembly.
4. Compress the Caliper Piston: This is crucial. Using a C-clamp or caliper compression tool, carefully compress the caliper piston. You may need to rotate the piston as you compress it. Be careful not to damage the piston or boot. Brake fluid will likely be expelled, so have a rag ready and consider wearing safety glasses.
5. Remove the Caliper: Locate and remove the bolts that hold the caliper to the caliper bracket. These are usually on the back of the caliper. Sometimes, you need to remove the slide pins first (using the correct size wrench), then remove the caliper itself. Support the caliper with a wire or bungee cord to keep it from hanging by the brake line.
6. Remove the Old Brake Pads: The old brake pads should now be easily accessible. They may be held in place by clips or pins; carefully remove them.
7. Clean the Caliper and Rotor: Use brake cleaner to thoroughly clean the caliper slides, caliper bracket, and the rotor surface.
8. Install the New Brake Pads: Install the new brake pads into their respective slots in the caliper bracket.
9. Reinstall the Caliper: Reinstall the caliper onto the bracket, making sure the slide pins are properly lubricated (use a caliper pin lubricant or high-temperature grease). Tighten the caliper bolts to the manufacturer's specified torque (consult your repair manual).
10. Reinstall the Wheel: Install the wheel and tighten the lug nuts. Don't fully tighten them yet.
11. Lower the Vehicle: Carefully lower the vehicle to the ground.
12. Final Tightening: Tighten the lug nuts to the manufacturer's specified torque.
13. Test the Brakes: Carefully test the brakes several times to ensure they are working properly. You may need to pump the brakes a few times initially to build up pressure.
Important Considerations:
* Consult a Repair Manual: A repair manual specific to your 2002 Ford Explorer is highly recommended. It will provide detailed diagrams and torque specifications.
* Brake Fluid: If you significantly compress the brake piston, you may need to bleed the brakes afterward to remove any air bubbles that may have entered the system. This is a more advanced procedure.
* Rotor Condition: Inspect your brake rotors. If they are excessively worn or scored, they'll need to be replaced as well.
* Professional Help: If you're unsure about any step or encounter unexpected problems, it's always best to take your vehicle to a qualified mechanic.
This information is for guidance only. Always prioritize safety and refer to a repair manual for detailed instructions specific to your vehicle. Incorrectly performed brake work can be extremely dangerous.
