How to replace the rear brake pads on a 1995 through 2001 Ford Explorer
The system utilizes a drum-in-hat type rear brake rotor. The integral drum allows the use of a drum-and-shoe type parking brake system. All other components are similar to their front disc brake components
Remove the two bolts on either side of the brake hose with the rubber boots. Do not remove the four bolts where the axle ties in. The two bolts to be removed require a 10mm socket/wrench. Loosen the pads from the caliper
Rotor Removal
In order to take the rotors off (replace with new or have them machined), it is best to loosen the emergency brake shoes. To do this, behind the rotors, in the back there is a rubber plug, remove that and you can use a screw driver to engage the teeth of the adjusting screw, turn it clockwise to loosen, usually 10-20 teeth. Usually this means turn it downward. After this, it may still be difficult to get the rotors off without tapping them. Use a rubber mallet and hit them from behind. Before really whacking the rotor, make sure you have loosened the adjusting screw enough. It may take heavy swings of the rubber hammer to do this. It will eventually break loose.
Parking Brake
You might want to check the parking brake while you are here.
To remove:
- Remove the rear disc brake rotor.
- Remove the outboard return spring.
- Remove the adjusting screw spring.
- Remove the rear brake shoe hold-down spring and pin.
- Remove the brake shoe adjusting screw and nut.
- Remove the front brake shoe hold-down spring and pin.
- Remove both parking brake shoes and the inboard return spring.
- Check the parking brake lever for excessive wear and replace as necessary.
To install:
- Position the front parking brake shoe to the backing plate and install the hold-down pin and spring.
- Install the rear parking brake shoe with the inboard return spring.
- Position the brake shoe adjuster screw and nut on the shoes and install the rear shoe hold-down pin and spring.
- Install the brake shoe adjuster spring.
- Install the outboard return spring.
- Adjust the parking brake shoes and install the rotor, caliper and wheel.
- Lower the vehicle and tighten the wheel lug nuts to 100 ft. lbs. (135 Nm).
ADJUSTMENT
- Measure the inside of the drum portion of the rear brake rotor
- Remove the rear disc brake rotor.
- Using Brake Adjustment Gauge D81L-1103-A or equivalent, measure the inside diameter of the drum portion of the rear disc brake rotor.
- Subtract 0.020 in. (0.508mm) from the first measurement, adjust the brake shoes to that size
- Adjust the parking brake adjuster screw until the outside diameter of the parking brake shoes measures 0.020 in. (0.508mm) less than the drum measurement.
- Install the rear disc brake rotor.
Reassembly
Reassembly is easy. Put new or machined rotors back on by sliding them over the lugs (they should slide on easily.) Loosen bleeder valve (having a catch bottle handy is good). Push calipers in slowly (using a c-clamp or large channel lock pliers), close bleeder valve. Put on pads. Lubricate metal clips with small amount of anti-seize.
Re-adjust the emergency brake by turning the opposite direction from loosening.
Refill the brake master cylinder
CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The guide pins are meant to be sealed for life and are not repairable. Use Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A for re-lubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in contamination and accelerated corrosion or wear of the caliper slide pin mechanism. 
CAUTION: Use a hub-mount brake lathe if necessary to machine the rear brake disc. 
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