🔧 Explorer - Front Brake Pad Replacement

You’ll be removing the front wheels, lifting the brake caliper off the rotor, swapping the pads (and hardware if included), then reinstalling everything and pumping the brake pedal to restore pedal feel. This is routine wear maintenance, but it’s safety-critical—take your time and keep everything clean.

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

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⚠️ Safety & Precautions

• 🛑 Support your Explorer on jack stands—never work under a vehicle held only by a jack.
• 🛑 Do not press the brake pedal while the caliper is off the rotor (the piston can pop out).
• 🛑 Brake dust is harmful—use brake cleaner, not compressed air, to clean parts.
• 🛑 Keep grease off pad friction material and the rotor braking surface.
• 🛑 Brake fluid can damage paint—wipe spills immediately.
• 🔋 Battery disconnect is not required for this 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
• 1/2" drive breaker bar
• 1/2" drive torque wrench (20-200 ft-lbs range)
• 13mm socket
• 18mm socket
• Ratchet (3/8" drive)
• 3/8" drive torque wrench (10-80 ft-lbs range)
• Large C-clamp (6" or larger)
• Brake cleaner
• Wire brush
• Pick tool
• Bungee cord
• Disposable 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 (clips/shims) - Qty: 1
• Brake caliper slide pin grease (silicone) - Qty: 1
• Brake fluid (DOT 3) - Qty: 1 bottle

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📋 Before You Begin

• 🅿️ Park on level ground, turn the wheel straight, and set the parking brake.
• 🧱 Place wheel chocks behind the rear tires.
• 🧴 Open the hood and check the brake fluid level in the reservoir. If it’s near “MAX,” siphon a little out (compressing pistons can raise the level).
• 🧰 Lay out your new pads and hardware. Match them side-by-side with the old pads before installing.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Loosen lug nuts and lift the front

• Use a 19mm socket and breaker bar to loosen the front lug nuts about 1/2 turn while the tire is still on the ground.
• Lift the front with a floor jack (rated 3-ton minimum) at the front jacking point/crossmember, then set the frame on jack stands (rated 3-ton minimum).
• Remove the lug nuts using a 19mm socket, then remove the wheel.

Step 2: Locate the caliper and remove the slide pin bolts

• Turn the steering wheel slightly if needed for better access.
• On the back side of the caliper are the slide pin bolts (they hold the caliper to the bracket).
• Use a 13mm socket and ratchet (3/8" drive) to remove the two caliper slide pin bolts.
• Tip: Keep bolts in order—top and bottom.

Step 3: Lift the caliper off and support it

• Carefully lift the caliper off the rotor by hand.
• Use a bungee cord to hang the caliper from the suspension spring/arm.
• Do not let the caliper hang by the brake hose.

Step 4: Remove old pads and hardware

• Pull the old inner and outer pads out of the caliper bracket by hand.
• If your new pads include new stainless clips, remove the old clips using a pick tool.
• Clean the pad “rails” (where the clips sit) using a wire brush and brake cleaner.

Step 5: Compress the caliper piston

• Place one old brake pad against the piston face.
• Use a large C-clamp (6" or larger) to slowly press the piston back into the caliper.
• A C-clamp is a screw clamp that pushes the piston in evenly as you tighten it.
• Watch the brake fluid reservoir while you compress—do not let it overflow.

Step 6: Lube contact points and install new hardware

• Install the new pad clips into the bracket by hand (they should snap/seat flat).
• Apply a thin film of brake caliper slide pin grease (silicone) on the clip contact points where the pads “ears” slide.
• Do not get grease on the rotor face or pad friction material.

Step 7: Install the new pads

• Install the inner and outer pads into the bracket by hand.
• Make sure they slide freely in the clips (no binding). If tight, re-clean the rails using a wire brush and brake cleaner.

Step 8: Reinstall the caliper and torque the bolts

• Lower the caliper over the new pads and rotor by hand.
• Install the slide pin bolts by hand first (to avoid cross-threading).
• Tighten using a 13mm socket and ratchet (3/8" drive), then final-tighten using a 3/8" drive torque wrench.
• Torque to 35 Nm (26 ft-lbs) for the caliper slide pin bolts.

Step 9: Reinstall the wheel and torque lug nuts

• Reinstall the wheel and hand-thread all lug nuts.
• Lower the vehicle off the jack stands using the floor jack (rated 3-ton minimum).
• Torque lug nuts in a star pattern using a 1/2" drive torque wrench.
• Torque to 135 Nm (100 ft-lbs) for the lug nuts.

Step 10: Repeat on the other front side

• Repeat Steps 1–9 for the other front wheel.
• Replace front pads as an axle set (both sides).

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✅ After Repair

• 🦶 With the engine OFF, pump the brake pedal 10–15 times until it feels firm (this seats the pistons against the new pads).
• 🧴 Recheck brake fluid level and top off with DOT 3 if needed.
• 🔍 Look around both calipers for any signs of brake fluid leaks.
• 🚗 Do a cautious test drive. Start with slow stops in a safe area.
• 🛑 Pad bed-in: make 8–10 medium stops from ~50 km/h to ~10 km/h, with light driving between stops to cool. Avoid hard stops for the first 200 km.

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💰 DIY vs Shop Cost

Shop Cost: ₹4,500-₹9,000 (parts + labor)

DIY Cost: ₹1,800-₹4,500 (parts only)

You Save: ₹2,700-₹4,500 by doing it yourself!

Shop labor rates vary but typically run ₹800-₹1,500/hour. This repair takes a shop approximately 1.0-1.5 hours.

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🎯 Ready to get started?

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