Tools You'll Need:
* Jack and jack stands (Crucial for safety)
* Lug wrench
* Wheel chocks
* Socket wrench set (metric)
* Wrenches (metric)
* Brake caliper compression tool (highly recommended)
* C-clamp (can be used as a substitute for a caliper compression tool, but less safe and effective)
* Pliers
* Wire brush
* Brake cleaner
* New brake pads (ensure they're the correct type for your Expedition)
* New rotors (likely needed, especially if the old ones are worn or scored)
* Anti-seize lubricant
* Torque wrench (essential for proper tightening)
* Gloves
Procedure (Front Brakes - similar for rear, but with potential differences):
1. Safety First: Park on a level surface, engage the parking brake, and chock the rear wheels. Use jack stands under the frame near the wheels, NEVER rely solely on the jack.
2. Remove the Wheel: Loosen the lug nuts slightly with the lug wrench before jacking up the vehicle. Jack up the vehicle and securely place it on jack stands. Remove the lug nuts completely and remove the wheel.
3. Inspect the Brakes: Carefully examine the brake pads and rotors for wear and tear. Measure the pad thickness; if they're too thin (check your owner's manual or parts store for minimum thickness), they need replacing. Inspect the rotors for scoring, grooves, or excessive rust. Usually, rotors need replacing if the pads are worn.
4. Remove the Caliper: Use the appropriate wrench to remove the caliper mounting bolts. Once the bolts are out, carefully support the caliper with a bungee cord or wire to keep it from hanging by the brake line. Do not let the brake line hang freely; this could damage it.
5. Compress the Caliper Piston: Use a caliper compression tool to push the piston back into the caliper. This is necessary to make room for the new, thicker brake pads. A C-clamp can be used but is more cumbersome and potentially damaging to the piston seal.
6. Remove the Old Brake Pads: Remove the old brake pads; they should slide out easily. Clean the caliper bracket and sliding surfaces with a wire brush and brake cleaner.
7. Install the New Brake Pads: Carefully install the new brake pads into the caliper bracket.
8. Install the Rotor (if replacing): If replacing the rotor, clean the hub thoroughly and install the new rotor. Some rotors are press-fit while others use mounting bolts. Check your repair manual.
9. Reinstall the Caliper: Carefully reinstall the caliper, ensuring it slides freely in the caliper bracket. Tighten the caliper mounting bolts to the manufacturer's specified torque.
10. Reinstall the Wheel: Reinstall the wheel and tighten the lug nuts in a star pattern (opposite nuts). Lower the vehicle to the ground and fully tighten the lug nuts.
11. Repeat for other Wheels: Repeat steps 2-10 for the other front wheel, and then the rear wheels (rear brakes might have a slightly different procedure, especially if they are drum brakes instead of disc brakes).
12. Pump the Brakes: Pump the brake pedal several times to ensure the brakes are working correctly.
13. Test Drive: Take a short test drive to confirm the brakes are working properly.
Important Notes:
* Bleeding the Brakes: If you've worked on the brake system, it's highly recommended to bleed the brakes to remove any air that might have entered the system. This is best done with a helper.
* Rear Brakes: The rear brakes on some 1999 Ford Expeditions may be drum brakes, requiring a different procedure for replacement. Consult your repair manual.
* ABS: If your Expedition has an anti-lock braking system (ABS), there may be additional considerations.
* Torque Specifications: Always refer to your vehicle's repair manual for the correct torque specifications for all bolts and nuts. Using the wrong torque can damage components or lead to unsafe braking.
This is a simplified explanation. Use a repair manual specific to your 1999 Ford Expedition for detailed instructions and diagrams. Remember, brake safety is paramount. If you're not confident in your abilities, have a qualified mechanic perform the repair.
