🔧 Express - Front Brake Pad Replacement

You’ll remove the front wheels, swing the front brake calipers out of the way, swap in new pads (and hardware clips), then reassemble and safely seat the pads. This restores braking performance and prevents pad-to-rotor damage when pads get thin.

Difficulty Level: Intermediate | Estimated Time: 1.5-3 hours

Assumption: Stock front disc brakes on your Express.

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⚠️ Safety & Precautions

• 🛑 Support the van with jack stands on the frame—never rely on a floor jack.
• 🛞 Chock the rear wheels and keep the transmission in PARK.
• 🔥 Brakes get extremely hot—work only when components are cool.
• 🧴 Brake dust is hazardous—use brake cleaner, not compressed air.
• 🚫 Do not press the brake pedal with the caliper removed (it can push the pistons out).
• 🔧 If brake fluid rises in the reservoir, remove a little with a suction tool to prevent overflow.

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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
• 1/2" drive breaker bar
• 1/2" drive torque wrench (20-200 ft-lbs range)
• 22mm deep socket
• Metric socket set 10mm-24mm (1/2" drive)
• Ratchet (1/2" drive)
• Flat-blade screwdriver
• C-clamp (6" minimum)
• Small bungee cord
• Wire brush
• Brake parts cleaning brush
• Catch pan
• Disposable 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 pad hardware kit (abutment clips) - Qty: 1
• Brake caliper grease (silicone) - Qty: 1
• Brake cleaner - Qty: 2
• Brake fluid (DOT 3) - Qty: 1
• Front brake rotors - Replace in pairs - Qty: 2 (optional if worn/pulsation)

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📋 Before You Begin

• 🧭 Park on level ground, set the parking brake, and chock both rear wheels.
• 🧰 Loosen the front wheel lug nuts slightly before lifting (use a 22mm deep socket and breaker bar).
• 🧴 Pop the hood and locate the brake fluid reservoir; keep the cap loosely set on top to prevent splashes.
• 🔎 Turn the steering wheel to give yourself access to the caliper you’re working on.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Lift and secure the front

• Use a floor jack (rated 3-ton minimum) to lift the front at the proper front jacking point.
• Set the van onto jack stands (rated 3-ton minimum) under the frame and gently lower the jack.
• Leave the floor jack lightly supporting as a backup (not holding full weight).

Step 2: Remove the front wheels

• Remove lug nuts using a 22mm deep socket and ratchet (1/2" drive).
• Remove both front wheels and slide them under the van as an added safety backup.

Step 3: Check fluid level and prep the caliper

• Look at the brake fluid level in the reservoir; if it’s near MAX, use a catch pan and remove a small amount (so it won’t overflow when pistons are pushed back).
• Use safety glasses and spray the caliper/pad area with brake cleaner.

Step 4: Remove the caliper from the bracket

• Locate the two caliper slide/guide bolts on the back side of the caliper.
• Use your metric socket set 10mm-24mm with a ratchet (1/2" drive) to remove the caliper slide/guide bolts (choose the socket that fits snugly).
• Carefully lift the caliper off the rotor.
• Hang the caliper using a small bungee cord so it doesn’t pull on the brake hose.

Step 5: Remove old pads and hardware clips

• Slide the old pads out of the caliper bracket by hand. Use a flat-blade screwdriver if they’re stuck.
• Remove the old abutment clips (hardware) from the bracket using a flat-blade screwdriver.
• Use a wire brush to clean the pad “lands” (the metal ledges where the clips sit) until smooth.

Step 6: Push the caliper pistons back

• A C-clamp is a screw clamp used to press the pistons back slowly and evenly.
• Place an old pad against the pistons, then use a C-clamp (6" minimum) to slowly compress the pistons fully into the caliper.
• Go slowly and watch the brake fluid reservoir level as you compress.

Step 7: Install new hardware clips and grease contact points

• Snap the new hardware/abutment clips into the bracket by hand.
• Apply a thin film of brake caliper grease (silicone) to the pad ears where they touch the clips (do not get grease on pad friction material or rotor).
• Thin grease only—more is not better.

Step 8: Install the new pads

• Install the inner and outer pads into the bracket in the same orientation as the originals.
• If your pad set includes wear indicators, install them in the same position as the old setup.
• Make sure pads slide freely in the clips (no binding).

Step 9: Reinstall the caliper

• Lower the caliper back over the new pads/rotor.
• Reinstall the caliper slide/guide bolts using a ratchet (1/2" drive).
• Torque to 100 Nm (74 ft-lbs) for the caliper slide/guide bolts.

Step 10: Repeat on the other front wheel

• Repeat Steps 3 through 9 on the opposite front side.

Step 11: Reinstall wheels and torque lug nuts

• Reinstall the wheels and hand-thread all lug nuts.
• Snug lug nuts in a star pattern using a 22mm deep socket and ratchet (1/2" drive).
• Lower the van off the jack stands (rated 3-ton minimum) using the floor jack (rated 3-ton minimum).
• Final-tighten lug nuts in a star pattern with a 1/2" drive torque wrench (20-200 ft-lbs range): Torque to 190 Nm (140 ft-lbs).

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✅ After Repair

• 🦶 With the engine OFF, slowly pump the brake pedal 8-12 times until it feels firm (this seats the pistons against the new pads).
• 🧴 Recheck brake fluid level; top off with DOT 3 if needed (do not overfill).
• 🚐 Start the engine and hold the brake pedal; confirm it stays firm and does not sink.
• 👀 Check both front calipers for any fluid seepage and confirm the brake hoses aren’t twisted.
• 🛣️ Bed-in (seat) the pads: make 6-10 moderate stops from ~30 mph down to ~5 mph, allowing a little cooling between stops. Avoid hard panic stops for the first 200 miles.

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💰 DIY vs Shop Cost

Shop Cost: $350-$700 (parts + labor)

DIY Cost: $80-$220 (parts only)

You Save: $270-$480 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 1.5-3 hours.

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🎯 Ready to get started?

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