🔧 Passport - Front Brake Pads & Rotor Replacement

You’ll remove the front calipers, replace the brake pads, and swap the front rotors. New rotors give the pads a flat, clean surface so braking stays smooth and quiet.

Difficulty Level: Intermediate | Estimated Time: 2-4 hours

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⚠️ Safety & Precautions

• 🛑 Support your Passport with jack stands—never rely on a jack alone.
• 🔥 Brakes can be extremely hot; let them cool before starting.
• 🧪 Brake dust is harmful—use brake cleaner, not compressed air.
• 🪢 Do not let the caliper hang by the hose—support it with a bungee cord.
• 🔋 Battery disconnect is not required for this front brake job.

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🔧 Required Tools

You'll need the following tools for this repair:

• Floor jack (rated 3-ton minimum)
• Jack stands (rated 3-ton minimum)
• Wheel chocks
• 19mm socket
• 17mm socket
• 14mm socket
• 3/8" ratchet
• 1/2" breaker bar
• Torque wrench (20-150 ft-lbs range)
• Flathead screwdriver
• C-clamp (6" minimum) or disc brake piston compressor (specialty)
• Bungee cord
• Wire brush
• Rubber mallet
• Impact screwdriver (specialty)
• Phillips #3 bit
• Brake cleaner spray
• Shop towels
• Nitrile gloves
• Safety glasses

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Front brake pad set - Qty: 1
• Front brake rotors - Qty: 2
• Front pad hardware kit (abutment clips) - Qty: 1
• Brake caliper grease (silicone) - Qty: 1
• Brake cleaner - Qty: 2 cans
• DOT 3 brake fluid - Qty: 1 quart

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📋 Before You Begin

• 🧭 Park on level ground, shift to Park, and set the parking brake.
• 🧱 Place wheel chocks behind the rear wheels.
• 🔓 Crack the front lug nuts loose (do not remove) using a 19mm socket and breaker bar.
• 🧴 Pop the hood and remove the brake fluid reservoir cap. Watch fluid level while compressing pistons.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Lift and remove the front wheels

• Lift the front of your Passport using a floor jack (rated 3-ton minimum) at the front jacking point.
• Set it securely on jack stands (rated 3-ton minimum).
• Remove the lug nuts with a 19mm socket and take off both front wheels.

Step 2: Remove the front caliper (pads stay in it)

• Turn the steering wheel to give yourself working room.
• Remove the 2 caliper slide bolts using a 14mm socket and 3/8" ratchet.
• Lift the caliper off the bracket and support it with a bungee cord.
• Never let the caliper hang by the hose.

Step 3: Remove the old pads and hardware

• Pull the inner and outer pads out by hand. Use a flathead screwdriver if they’re stuck.
• Remove the pad abutment clips (hardware) from the bracket.

Step 4: Remove the caliper bracket

• Remove the 2 caliper bracket bolts using a 17mm socket and breaker bar.
• Set the bracket aside.
• On reassembly: Torque to 108 Nm (80 ft-lbs).

Step 5: Remove the rotor

• If your Passport has rotor retaining screws, remove them using an impact screwdriver (specialty) with a Phillips #3 bit.
• Pull the rotor off the hub. If it’s stuck, tap around the rotor “hat” with a rubber mallet.
• Clean the hub face with a wire brush and spray with brake cleaner spray, then wipe with shop towels.

Step 6: Install the new rotor

• Clean both sides of the new rotor with brake cleaner spray and shop towels (removes shipping oil).
• Install the rotor onto the hub. If you’re reusing retaining screws, reinstall them using the impact screwdriver (specialty) and Phillips #3 bit until snug.

Step 7: Reinstall the bracket with new hardware clips

• Snap the new abutment clips from the hardware kit into the bracket by hand.
• Reinstall the bracket bolts using a 17mm socket and 3/8" ratchet to start, then tighten with a torque wrench.
• Torque to 108 Nm (80 ft-lbs).

Step 8: Compress the caliper piston

• Place an old pad against the piston face, then compress the piston slowly using a C-clamp (6" minimum) or disc brake piston compressor (specialty).
• Go slowly and keep an eye on the brake fluid reservoir so it doesn’t overflow.
• Slow compression helps prevent seal damage.

Step 9: Install the new pads

• Apply a thin film of brake caliper grease (silicone) where the pad “ears” touch the abutment clips (metal-to-metal contact points only).
• Install the inner and outer pads into the bracket by hand.

Step 10: Reinstall the caliper

• Lower the caliper over the new pads.
• Reinstall the 2 caliper slide bolts using a 14mm socket.
• Tighten with a torque wrench: Torque to 34 Nm (25 ft-lbs).

Step 11: Repeat on the other front side

• Repeat Steps 2 through 10 on the other front wheel.
• Do one side at a time to avoid mix-ups.

Step 12: Reinstall wheels and torque lug nuts

• Reinstall both front wheels and hand-thread the lug nuts.
• Lower the vehicle to the ground using the floor jack (rated 3-ton minimum).
• Tighten lug nuts in a star pattern using a torque wrench: Torque to 127 Nm (94 ft-lbs).

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✅ After Repair

• 🦶 Pump the brake pedal 10–15 times until it feels firm before driving.
• 🧴 Check brake fluid level and top off with DOT 3 brake fluid if needed (do not overfill).
• 👀 Check for leaks around the calipers and verify the hoses aren’t twisted.
• 🧪 Road test at low speed first, then do a gentle bed-in: 6–8 moderate stops from 40 to 10 mph, allowing a little cooling between stops.

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💰 DIY vs Shop Cost

Shop Cost: $550-$950 (parts + labor)

DIY Cost: $220-$480 (parts only)

You Save: $330-$470 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 2-3 hours.

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🎯 Ready to get started?

HowToo makes it easy: same-day/2-day shipping on every part, plus all the tools and specialty tools you need! Check out the parts and tools sections below to add everything to your cart.