Here's a general overview. Always consult your vehicle's repair manual for specific instructions and torque specifications. These instructions are for general guidance only and may not be entirely accurate for your specific vehicle.
Tools You'll Need:
* Jack and jack stands (essential for safety!)
* Wheel chocks
* Lug wrench
* Socket wrench set (metric)
* Wrenches (metric)
* C-clamp or caliper piston compression tool
* Brake cleaner
* Grease (brake caliper grease, specifically)
* New rear brake pads
* Possibly a brake bleed kit (if you have to remove the caliper completely)
* Protective gloves and eye protection
Steps:
1. Safety First: Park on a level surface, engage the parking brake, and chock the front wheels. Jack up the rear of the vehicle and securely support it on jack stands. Never work under a vehicle supported only by a jack.
2. Remove the Wheel: Remove the lug nuts and take off the wheel.
3. Expose the Brake Caliper: You'll see the brake caliper clamping onto the rotor.
4. Remove the Caliper: There are typically two bolts holding the caliper to the caliper bracket. Unscrew these bolts and carefully remove the caliper. Support the caliper with a bungee cord or wire to prevent it from dangling and damaging the brake line.
5. Compress the Caliper Piston: This is the crucial step. The piston needs to be compressed to make room for the new, thicker brake pads. Use a C-clamp or a specialized caliper piston compression tool. Be careful not to damage the piston seal. Compress the piston slowly and steadily. You may need to turn the piston as you compress it.
6. Remove the Old Brake Pads: The old brake pads should now be easily removable. There might be a retaining clip holding them in place; remove it if necessary.
7. Install the New Brake Pads: Install the new brake pads, ensuring they slide smoothly into their slots.
8. Reinstall the Caliper: Carefully slide the caliper back onto the brake rotor and securely fasten the caliper bolts to the caliper bracket. Do not over-tighten these bolts.
9. Check for Smooth Caliper Movement: Make sure the caliper slides freely back and forth on the caliper bracket.
10. Reinstall the Wheel: Reinstall the wheel and tighten the lug nuts.
11. Lower the Vehicle: Carefully lower the vehicle from the jack stands.
12. Bleed the Brakes (Possibly): If you completely removed the caliper, you may need to bleed the brakes to remove any air that might have entered the system. This is a separate procedure requiring a brake bleed kit and a helper. Consult your owner's manual or a repair manual for the correct bleeding procedure.
13. Test the Brakes: Before driving, carefully test the brakes several times to ensure they're working properly. The initial few stops might feel a bit softer as the new pads bed in.
Important Considerations:
* Rotor Inspection: Inspect the brake rotors for wear and tear. If they're excessively worn or damaged, they'll need to be replaced or turned (machined).
* Brake Fluid Level: Check your brake fluid level before and after the procedure. Low fluid levels may indicate a leak.
* Professional Help: If you're unsure about any step, seek professional help. Brake failure can have serious consequences.
This is a simplified guide. Refer to a repair manual specific to your 2004 Ford Freestar for detailed instructions and torque specifications. Safety is paramount when working on your brakes. Remember, this advice is for informational purposes only and does not constitute professional mechanical advice.
