Safety First:
* Use jack stands: Never work under a vehicle supported only by a jack.
* Wear safety glasses and gloves: Brake dust is irritating, and sharp parts exist.
* Disconnect the battery's negative terminal: This prevents accidental electrical shorts.
* Have a helper: This makes the job significantly easier.
Tools You'll Need:
* Jack and jack stands
* Wheel chocks
* Lug wrench
* Socket wrench set (metric)
* Torque wrench (crucial for proper tightening)
* C-clamp (or brake caliper compressor tool)
* Wire brush
* Brake cleaner
* Penetrating lubricant (PB Blaster or similar)
* Pry bar (plastic or metal, depending on your comfort level)
* Hammer (optional, for stubborn parts)
* New brake pads
* New rotors
* Anti-seize lubricant
Procedure:
1. Preparation:
* Park on a level surface, engage the parking brake, and chock the wheels.
* Locate your owner's manual to find the correct torque specifications for lug nuts, caliper bolts, and other fasteners.
2. Wheel Removal:
* 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. Caliper Removal:
* Locate the caliper mounting bolts: These are usually on the back of the caliper.
* Apply penetrating lubricant to the bolts if they're stuck.
* Remove the caliper bolts: Use the appropriate socket and wrench.
* Carefully remove the caliper: It might be hanging by the brake hose. You can use a bungee cord or wire to hang it up and out of the way, preventing stress on the brake hose.
4. Brake Pad Removal:
* Remove the old brake pads: They should simply slide out.
5. Rotor Removal:
* Depending on your Explorer, the rotors may be a direct bolt-on or require some additional steps. Some might need to remove a retaining screw or clip.
* If you have a hub-mounted rotor, you might need to remove a retaining nut on the wheel hub to take it off. This often requires specialized tools, so consult a repair manual.
* Remove the rotor: Once free, it should slide off the hub.
6. Cleaning and Inspection:
* Clean the hub and mating surfaces of the rotor with a wire brush. Remove any rust or debris.
* Inspect the caliper slides and pins: If they're rusty or seized, clean and lubricate them with high-temperature brake caliper grease.
* Inspect the brake hose: Check for cracks or damage. Replace if necessary.
7. Installation:
* Install the new rotors: Make sure they slide on smoothly.
* Install the new brake pads: Make sure they slide into their respective slots.
* Install the caliper: Make sure it slides smoothly and is properly seated. Tighten the caliper mounting bolts to the manufacturer's specified torque.
* Install the wheel: Tighten the lug nuts in a star pattern.
* Lower the vehicle: Lower the vehicle slowly and carefully.
* Tighten the lug nuts fully: Use a torque wrench to ensure proper tightening.
8. Bleeding the Brakes (Important):
* After replacing any brake components, bleeding the brakes is crucial to remove any air trapped in the system. This prevents spongy brakes and loss of stopping power. Look up the proper bleeding procedure for your Explorer. This often involves opening bleeder valves on each caliper while a helper presses the brake pedal.
9. Test Drive:
* After bleeding the brakes, test drive the vehicle. You should immediately notice improved braking. Listen for any unusual noises.
Important Considerations:
* Rust: Rust can be a significant problem, especially on older Explorers. Penetrating lubricant is your friend.
* Caliper slides and pins: These often seize, requiring significant effort to free. Sometimes replacement is necessary.
* Repair manual: A repair manual specific to your year and model Explorer is strongly recommended. It will provide detailed diagrams and instructions.
* Professional help: If you're uncomfortable with any aspect of this procedure, take your vehicle to a qualified mechanic. Brake failure is extremely dangerous.
This guide provides a general overview. Consult a repair manual for detailed, year-specific instructions. Always prioritize safety and seek professional assistance if needed. Improperly installed brakes can lead to serious injury or death.
