How do you replace front rotors on a 02 Ford Explorer 4x4
You will need a large C-clamp, a small block of wood, and a set of bigger allen wrenches
Remove the tire.
You will see a brake caliper assembly. This is what your brake pads are mounted to. The rotor spins in between your pads. There are two allen head bolts holding the caliper assembly to the mounts. You get to them from the back side of the assembly, so you'll have to put your head back into the fender-well to see them (I just feel around for them). There will be one close to the top and one close to the bottom of the assembly. You'll need a set of larger allen head wrenches, I think it is around a 1/4 inch or so. Try different sizes until you find the one that fits. Now is the hard part. You have to break the bolts loose and normally they are on pretty good. You can use a closed end box wrench or a piece of pipe to get better leverage on the allen wrench. I've even used a hammer to break em loose. And remember, the bolts are going towards you so you want to go the opposite of what you think. Go right to loosen ant left to tighten (from your point of view, outside the fender-well). Once you have both bolts out, pivot the top of the caliper back until the top clears the rotor, then slide the entire thing, pads and all, up. You now have the caliper assembly off. The brake line is still attached so you'll have to set it out of the way or use a zip tie to hang it up until you are done. I don't recommend just letting it hang by the brake line. Now you are looking at the rotor. It has 5 lugs coming through it. Some just pop off and others take a little gentle persuasion. Either way, you want to pull the rotor toward you and off of the hub. You can do this by putting presure on one side and then the other, then working back and forth like this until it comes off. Be careful if you are using any "tools" to do this. If you are going to be prying, be sure not to use a weak point to pry against, you don't want to bend anything. Now you rotor is off. Celebrate a little, not to much. Now clean your new rotor, really good, with brake cleaner (from a spray can). Once it is clean, put it in the old rotors place. Just line up the holes and push it in place. Because the new rotor is not encrusted with brake dust, it will hang loosely in place until the caliper assembly is installed over top of it. Now, because your new rotor is slightly thicker than the old worn one, you may need to open the pads a little so the caliper assembly will fit over the top of the rotor. Test the fit first. If you can not get the caliper back over the rotor you will need to spread the pads out a little. This is where you need the C-Clamp and block of wood. Take the outside pad off by pushing it to the inside of the caliper assembly. Once in the middle it will lift out (this would be a great time to slap on a pair of new pads, just replace the old with new before going on). Place the wood against the pad that is facing you. Open the clamp large enough to get on top of the wood block and around the back of the caliper. Now tighten the clamp until you feel a slight pressure. Stop. You need to go very slow at this point. Turn the clamp a 1/4 to 1/2 turn at a time. Let the caliper move back a second or two and repeat. You are pushing the caliper open. Do this until you open the caliper at least a 1/2 inch. Note: This causes the brake fluid level to rise inside the master cylinder resevoire. You will need to remove a tablespoon or so, so your fluid level does not overflow. Especially when doing the second side. Just watch to see if removing fluid is neccessary as you go. If not, great. Now that the caliper is pushed open take the clamp and block of wood out. Now put the pad you removed earlier back in its place. Make sure it moves back and forth. Open everything as wide as it will go. Now when you put the caliper assembly over the rotor it should slide into place, even if it is a bit snug. Be sure to hold the rotor tight to the hub when sliding the caliper in place. Everything has to be square for this to go back together. Replace the allen bolts, be sure they are tight. Replace the wheel. Your done. Do one side then the other. Watch your brake fluid level throughout the process. When both sides are done double check the fluid level one last time. Adjust as neccessary. Enjoy, you just saved yourself around 600.00 (if you went with the new brake pads). Rotors are around 30 to 50 dollars each at Advance Auto or Auto Zone. Pads are about 30 - 50 dollars per set (enough for both wheels).
Sep 01, 2009 |
2002 Ford Explorer