Tools You'll Need:
* Jack and jack stands: Essential for safety. Never work under a vehicle supported only by a jack.
* Wheel chocks: To prevent the van from rolling.
* Lug wrench: To remove the wheel.
* Socket wrench and sockets: Various sizes, likely including 1/2" drive for caliper bolts.
* C-clamp or caliper compression tool: To compress the caliper piston. A C-clamp works, but a dedicated tool is easier and safer.
* Pliers or brake caliper pliers: May be needed to help with caliper bolt removal.
* Wire brush or sandpaper: To clean caliper surfaces.
* Brake cleaner: To clean caliper and rotor surfaces.
* New brake pads: Ensure you get the correct pads for your E-250's year and model. Buy in pairs.
* Gloves: Protect your hands from grease and dirt.
* Safety glasses: Protect your eyes from flying debris.
* Torque wrench: Highly recommended to tighten bolts to the manufacturer's specifications.
Steps:
1. Safety First: Park on a level surface, engage the parking brake, and chock the rear wheels. Use the jack to raise the front end of the van, and securely place it on jack stands.
2. Remove the Wheel: Remove the lug nuts and carefully remove the wheel.
3. Expose the Caliper: You should now see the brake caliper assembly clamping onto the rotor.
4. Compress the Caliper Piston: Use the C-clamp or caliper compression tool to push the caliper piston back into the caliper. This creates space for the new, thicker brake pads. You may need to turn the piston while compressing to help it retract smoothly. Be careful not to damage the piston seal.
5. Remove the Brake Pads: There are usually retaining clips or pins holding the brake pads in place. These can be carefully pried out or removed with pliers. Remove the old brake pads.
6. Clean the Caliper and Rotor: Use a wire brush to clean any rust or debris from the caliper mounting surfaces and the rotor. Clean everything with brake cleaner.
7. Install the New Brake Pads: Carefully insert the new brake pads into the caliper. Ensure they are seated correctly.
8. Reinstall the Caliper: Carefully reattach the caliper to the caliper bracket. Tighten the caliper mounting bolts to the manufacturer's specified torque.
9. Reinstall the Wheel: Replace the wheel and tighten the lug nuts in a star pattern to ensure even pressure. Do not over-tighten.
10. Lower the Vehicle: Carefully lower the vehicle from the jack stands.
11. Check for Leaks: Inspect the caliper for any signs of brake fluid leaks.
12. Pump the Brakes: Gently pump the brake pedal several times to ensure the pads are making contact with the rotor.
13. Test Drive: Take a short test drive to ensure the brakes are functioning correctly.
Important Considerations:
* Brake Fluid: If you're significantly compressing the caliper piston, you may need to bleed the brakes afterward to remove any air bubbles. This is a more advanced procedure.
* Rotor Condition: Inspect the brake rotors for wear and tear. If they are excessively worn, scored, or warped, they will need to be replaced or machined.
* Caliper Condition: Check the calipers for leaks or damage. If there are issues, the calipers may need to be replaced.
This guide provides a general overview. Refer to a repair manual specific to your Ford E-250's year and model for detailed instructions and torque specifications. Improper brake repair can be extremely dangerous. If you are not comfortable performing this task, consult a professional mechanic.
