Tools You'll Need:
* Jack and jack stands: Absolutely essential for safety.
* Wheel chocks: Prevent the van from rolling.
* Lug wrench: To remove the wheels.
* Socket wrench set (metric): You'll need various sizes, likely including 13mm, 15mm, and possibly larger.
* C-clamp or brake caliper compressor: To compress the caliper piston. A C-clamp is cheaper but a caliper compressor is generally easier to use.
* Wrench or socket to remove caliper mounting bolts: Size will vary, consult your manual.
* Pliers or wire cutters: To remove the brake pad retaining clips.
* Brake cleaner: To clean the caliper and brake parts.
* New brake pads: Make sure you get the correct ones for your E350.
* Gloves: To keep your hands clean.
* Torque wrench: To tighten bolts to the manufacturer's specifications (crucial for safety).
* Penetrating lubricant (like PB Blaster): Can help loosen rusted bolts.
Procedure:
1. Safety First: Park on a level surface, engage the parking brake, and chock the rear wheels. Use the jack to lift the front of the van and securely place it on jack stands.
2. Remove the Wheel: Remove the lug nuts and take off the wheel.
3. Locate the Caliper: The brake caliper is the metal assembly that houses the brake pads and piston. It's usually bolted to the knuckle (part of the steering assembly).
4. Compress the Caliper Piston: This is crucial. Using the C-clamp or caliper compressor, carefully compress the brake caliper piston. You'll need to push it back into the caliper to make room for the new, thicker pads. Be careful not to damage the piston or boot. Some pistons may rotate as you compress them.
5. Remove the Caliper: Remove the bolts holding the caliper to the knuckle. Sometimes, you can just unbolt it and let it hang (using a bungee cord to keep it out of the way is a good idea); other times you might need to carefully maneuver it around some components.
6. Remove the Old Brake Pads: Usually, there are retaining clips holding the brake pads in place. Remove these clips and take out the old pads. Inspect them carefully; excessive wear or damage indicates the need for further inspection and potential rotor replacement.
7. Clean: Use brake cleaner to thoroughly clean the caliper, piston, and knuckle.
8. Install the New Brake Pads: Install the new brake pads, ensuring they slide easily into place.
9. Reinstall the Caliper: Remount the caliper to the knuckle, ensuring the bolts are tightened to the correct torque specification (found in your owner's manual).
10. Reinstall the Wheel: Put the wheel back on and tighten the lug nuts. Do not fully tighten them yet.
11. Lower the Vehicle: Carefully lower the vehicle to the ground using the jack.
12. Tighten Lug Nuts: Once the vehicle is on the ground, fully tighten the lug nuts to the manufacturer's specified torque.
13. Final Check and Test: Pump the brake pedal several times to ensure they are working correctly. Test drive the vehicle slowly and carefully to confirm proper braking function.
Important Considerations:
* Rotor Condition: Inspect your brake rotors for wear and scoring. If they're excessively worn or damaged, they'll need to be replaced or machined.
* Brake Fluid: Brake fluid level may drop slightly when compressing the piston. Check the brake fluid reservoir and top it off if necessary. *Never* remove fluid from the reservoir.
* Professional Help: If you're uncomfortable performing this task, it's best to take your E350 to a qualified mechanic. Improperly installed brakes are extremely dangerous.
This guide provides a general overview. Always consult your owner's manual and refer to a repair manual specific to your 2000 Ford E350 for detailed instructions and torque specifications. Safety should always be your top priority.
