Safety First!
* Engage the parking brake firmly. This is crucial.
* Chock the front wheels to prevent the vehicle from rolling.
* Wear safety glasses and gloves.
* Use jack stands to support the vehicle securely after lifting it with a jack. Never work under a vehicle supported only by a jack.
* Have the correct tools: This includes a jack, jack stands, socket wrench set (metric), various wrenches, brake caliper piston compression tool, C-clamp (possibly), wire brush, brake cleaner, new brake pads, rotors (if needed), wheel lug wrench, and potentially a torque wrench.
Steps:
1. Wheel Removal: Loosen the lug nuts on the rear wheel using the lug wrench before jacking up the vehicle. Jack up the vehicle and securely support it with jack stands. Remove the wheel.
2. Caliper Removal: The process here depends on whether your Express 3500 has drum brakes or disc brakes in the rear. Most likely, it has disc brakes.
* Disc Brakes: Locate the caliper mounting bolts. These are usually two bolts. Unscrew them and carefully remove the caliper. You may need to support the caliper with a wire or bungee cord to prevent it from hanging by the brake line.
3. Brake Pad Removal: The old brake pads should now be visible. Carefully remove the old pads. Note the orientation of the pads and any shims or clips – you'll need to put the new ones back the same way.
4. Caliper Piston Compression: Using a caliper piston compression tool, carefully compress the caliper piston. This is necessary to make room for the new, thicker brake pads. If you don't have a specialized tool, a C-clamp can sometimes work, but use caution to avoid damaging the piston.
5. Rotor Inspection (Disc Brakes): Inspect the rotors for wear, scoring, or excessive rust. If they're damaged, they need to be replaced.
6. Brake Pad Installation: Install the new brake pads, making sure they're oriented correctly.
7. Caliper Reinstallation: Carefully reinstall the caliper onto the mounting brackets and tighten the bolts to the manufacturer's specified torque.
8. Wheel Reinstallation: Put the wheel back on and tighten the lug nuts. Lower the vehicle to the ground.
9. Lug Nut Tightening: Once the vehicle is on the ground, tighten the lug nuts to the specified torque using a torque wrench.
10. Brake Bleeding (If Necessary): If you had to remove the brake line from the caliper, you'll need to bleed the brakes to remove any air that may have entered the system. This requires two people and a brake bleeder kit. Consult your repair manual for the correct bleeding procedure.
11. Test Drive: Carefully test the brakes, making sure they work properly before driving normally. Listen for any unusual noises.
Drum Brakes (Less Likely): If your vehicle has drum brakes, the process is different and involves removing the brake drum, then accessing the brake shoes, adjusting the wheel cylinders (potentially), and replacing the shoes. This is a more complex process and again, you absolutely need a repair manual for your specific vehicle.
Important Considerations:
* Torque Specifications: Always refer to your repair manual for the correct torque specifications for all bolts and nuts. Over-tightening can damage components, while under-tightening can lead to loosening and failure.
* Brake Fluid: If you're working with the brake lines, you may need to replenish the brake fluid. Use the correct type of brake fluid specified for your vehicle.
* Professional Help: If you're not comfortable performing this repair yourself, it's always best to take your vehicle to a qualified mechanic. Brake repair is crucial for safety.
This information is for guidance only. Improper brake repair can be extremely dangerous. Always prioritize safety and consult your vehicle's repair manual before attempting this repair.
