Here's a general outline. This is not a comprehensive guide and may not be perfectly accurate for your specific vehicle. Always consult your vehicle's repair manual for precise instructions and torque specifications.
Tools You'll Need:
* Jack and jack stands (Crucial for safety)
* Lug wrench
* Wheel chocks
* Socket wrench set (metric)
* Torque wrench (essential for proper tightening)
* C-clamp or brake caliper compression tool
* Wire or a bungee cord to secure the caliper
* Rotor removal tool (sometimes necessary to remove stubborn rotors)
* Clean rags or shop towels
* Penetrating lubricant (like PB Blaster)
* Brake cleaner
* Anti-seize compound (for new rotor mounting)
* New rear rotors and brake pads (if needed)
Steps:
1. Safety First: Park on a level surface, engage the parking brake, and chock the front wheels. Raise the rear of the vehicle securely using the jack and place it on jack stands. Never work under a vehicle supported only by a jack.
2. Remove the Wheel: Remove the lug nuts and carefully take off the wheel.
3. Remove the Caliper:
* Use a socket wrench to remove the caliper bolts. These bolts usually require a 14mm or 15mm socket.
* Carefully support the caliper – it's heavy and contains brake fluid. You can hang it using wire or a bungee cord to a nearby suspension component, making sure it doesn't put stress on the brake line. Do not let the brake line hang freely.
4. Compress the Caliper Piston: Use a C-clamp or caliper compression tool to push the piston back into the caliper. This creates space for the new, thicker rotor. Be prepared for brake fluid to leak out – have a rag ready.
5. Remove the Old Rotor: Sometimes the old rotor will slide right off. Other times, it might be stuck. A rotor removal tool can help if it's stuck fast. If you don't have one, carefully try to tap it off using a hammer and a block of wood (to avoid damaging the rotor or mounting hub).
6. Clean the Hub: Thoroughly clean the wheel hub mounting surface with brake cleaner. Remove any rust, debris, or old anti-seize.
7. Install the New Rotor: Apply a thin layer of anti-seize compound to the hub mounting surface. Carefully slide the new rotor onto the hub.
8. Reinstall the Caliper: Reinstall the caliper onto the new rotor, making sure it's seated properly. Tighten the caliper bolts to the manufacturer's specified torque (check your repair manual).
9. Reinstall the Wheel: Carefully put the wheel back on and tighten the lug nuts. Do not fully tighten them yet.
10. Lower the Vehicle: Carefully lower the vehicle to the ground.
11. Torque the Lug Nuts: Fully tighten the lug nuts using a torque wrench to the manufacturer's specified torque.
12. Check for Leaks: Inspect for any brake fluid leaks around the caliper and wheel hub.
13. Test the Brakes: Before driving, carefully test the brakes several times to ensure they are functioning correctly.
Important Considerations:
* Brake Pads: Inspect your brake pads while the caliper is off. If they're worn down, replace them as well. This is a crucial safety measure.
* Bleeding the Brakes: In some cases, you may need to bleed the brakes to remove any air that might have entered the system during the repair. This requires a helper and a bleeding kit.
* Repair Manual: This is the most crucial piece of information. It will give you precise torque specifications, diagrams, and step-by-step instructions specific to your 2006 Ford Freestyle.
Again, if you're not comfortable performing this repair, take your vehicle to a qualified mechanic. Brake safety should never be compromised.
