🔧 Explorer - Rear Brake Pads & Rotors Replacement

You’ll be removing the rear wheels, taking off the calipers and rotors, retracting the parking-brake caliper pistons, then installing new rotors and pads on your Explorer. This restores braking power and stops vibration or grinding from worn parts.

Difficulty Level: Intermediate | Estimated Time: 2–3 hours

---

⚠️ Safety & Precautions

• ⚠️ Always work on a cool brake system; hot rotors and calipers can burn you.
• ⚠️ Support the Explorer with jack stands, never rely only on a floor jack.
• ⚠️ Wear safety glasses and a dust mask; brake dust is harmful to breathe.
• ⚠️ Your Explorer has an electronic parking brake (EPB) at the rear. Never run the EPB while calipers are off the rotors.
• ⚠️ You will disconnect the negative battery cable to keep the EPB from moving while you work.
• ⚠️ After opening the brake system, avoid getting fluid on paint; it can damage the finish.

---

🔧 Required Tools

You'll need the following tools for this repair:

• 🛠️ Floor jack (rated 3-ton minimum)
• 🛠️ Jack stands (rated 3-ton minimum, Qty: 2–4)
• 🛠️ Wheel chocks
• 🛠️ 19mm socket
• 🛠️ Breaker bar 1/2"
• 🛠️ Torque wrench 1/2" drive (10–150 ft-lb range)
• 🛠️ Torque wrench 3/8" drive (10–60 ft-lb range)
• 🛠️ 13mm socket
• 🛠️ 15mm socket
• 🛠️ 3/8" hex bit socket
• 🛠️ Torx T30 bit or screwdriver
• 🛠️ Torx T40 bit or socket
• 🛠️ Ratchet 3/8"
• 🛠️ Ratchet 1/2"
• 🛠️ Short and long extensions 3/8"
• 🛠️ Flathead screwdriver (medium)
• 🛠️ Needle-nose pliers
• 🛠️ Brake caliper compression / wind-back tool (specialty)
• 🛠️ C-clamp 6"
• 🛠️ Wire brush (small, steel)
• 🛠️ Bungee cord or mechanics wire
• 🛠️ Catch pan or drip tray
• 🛠️ Turkey baster or fluid suction tool
• 🛠️ Brake bleeder hose and bottle (simple manual kit)
• 🛠️ Shop rags
• 🛠️ Rubber or nitrile gloves
• 🛠️ Safety glasses
• 🛠️ Dust mask or respirator

---

🔩 Required Parts

HowToo sells all the parts you need for this repair:

• 🔩 Rear brake rotor (left) - Qty: 1
• 🔩 Rear brake rotor (right) - Qty: 1
• 🔩 Rear brake pad set - Qty: 1 set (serves both sides)
• 🔩 Rear brake hardware kit (pad clips / springs) - Qty: 1
• 🔩 Brake cleaner spray - Qty: 2 cans
• 🔩 High-temp silicone brake grease - Qty: 1 tube
• 🔩 Anti-seize compound (small tube) - Qty: 1
• 🔩 DOT 4 brake fluid - Qty: 1 liter
• 🔩 Caliper bracket bolts (rear, optional if corroded) - Qty: 4
• 🔩 Rotor retaining screws Torx (optional if damaged) - Qty: 2

---

📋 Before You Begin

• Park the Explorer on level ground, shift to PARK, and apply the parking brake firmly.
• Loosen the rear wheel lug nuts 1/2 turn with the 19mm socket while the vehicle is still on the ground.
• Open the hood and locate the brake fluid reservoir; you’ll be watching the fluid level as you push pistons back.
• Use a turkey baster or fluid suction tool to remove a small amount of fluid if the reservoir is very full.
• Turn ignition off, wait 2–3 minutes, then disconnect the negative battery terminal with the correct wrench or socket to disable the EPB from moving while you work.
• Chock the front wheels with wheel chocks to prevent any movement.

---

🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Raise and Support the Rear of the Explorer

• Use the floor jack at the rear jacking point (center of rear crossmember) to lift the back of the vehicle.
• Place jack stands under the approved rear pinch weld or frame points on both sides; slowly lower the vehicle onto the stands.
• Double-check stability by gently rocking the vehicle by hand.
• Remove the rear lug nuts with the 19mm socket and breaker bar, then remove both rear wheels.

Step 2: Access the Rear Caliper and EPB Motor

• Locate the rear brake caliper on one side; you will see a small electric motor bolted to the caliper (this is the EPB motor).
• Spray the caliper area and bolts lightly with brake cleaner to remove loose dust.
• Use the Torx T30 or T40 bit (depending on your caliper) with a 3/8" ratchet to remove the EPB motor mounting bolts from the back of the caliper.
• Gently pull the EPB motor straight back; let it hang from the wiring is risky, so support it with a bungee cord.
• Don’t twist or pry the EPB motor

Step 3: Retract the Rear Caliper Piston Manually

• With the EPB motor removed, you will see an internal drive where the motor shaft engaged.
• Insert the 3/8" hex bit socket into this drive and attach your 3/8" ratchet.
• Turn the hex drive slowly clockwise to retract the caliper piston fully. You should feel it turning and moving in.
• Watch the brake fluid reservoir; if the fluid rises too high, remove some with the turkey baster.
• Fully retract piston or new pads won’t fit

Step 4: Remove the Caliper and Old Pads

• Locate the two caliper slide pin bolts on the back of the caliper.
• Use the 13mm socket and 3/8" ratchet to remove the caliper slide bolts.
• Carefully slide the caliper off the rotor; hang it from the suspension spring using a bungee cord to avoid stressing the brake hose.
• Remove the old inner and outer pads from the caliper bracket by hand or with a flathead screwdriver to pry gently.

Step 5: Remove the Caliper Bracket and Rotor

• Use the 15mm socket and 1/2" breaker bar to remove the two caliper bracket bolts holding the bracket to the knuckle.
• Take off the caliper bracket and set it on a clean surface.
• If your rotor has a retaining screw, remove it using the Torx T30 bit and 3/8" ratchet or screwdriver.
• Slide the rotor off the hub. If stuck, tap around the rotor hat with a rubber mallet (not metal) to break rust free.
• If very rusty, apply penetrating oil and wait

Step 6: Clean and Prepare the Hub and Bracket

• Use the wire brush to clean rust and debris from the face of the hub where the rotor sits.
• Apply a very thin film of anti-seize compound to the hub face to reduce future rust (avoid the wheel stud threads).
• On the caliper bracket, remove old pad clips/hardware using needle-nose pliers.
• Clean the pad contact areas on the bracket with the wire brush and spray with brake cleaner; let dry.
• Install the new pad clips from the hardware kit onto the bracket by hand.
• Apply a tiny amount of high-temp brake grease to the areas where pad ears contact the clips (do not get grease on pad friction surfaces or rotor).

Step 7: Install the New Rotor

• Clean the new rotor on both sides with brake cleaner and a clean rag to remove the protective oil coating.
• Place the new rotor onto the hub, aligning with the wheel studs.
• If your vehicle uses a rotor retaining screw, reinstall it with the Torx T30 bit and snug it by hand; do not overtighten.

Step 8: Reinstall Caliper Bracket and Install New Pads

• Position the caliper bracket back over the rotor.
• Install the caliper bracket bolts by hand first, then tighten with the 15mm socket and 1/2" ratchet.
• Torque the caliper bracket bolts to 115 Nm (85 ft-lb) with the 1/2" torque wrench.
• Install the new brake pads into the bracket, making sure the inner pad with the wear indicator (if present) goes on the inside.
• Slide the pads into the clips until they seat firmly.

Step 9: Refit the Caliper Over New Pads

• Confirm the caliper piston is fully retracted; if not, use the 3/8" hex bit again to retract more.
• Place the caliper over the new pads and bracket.
• Install the caliper slide bolts by hand, then tighten with the 13mm socket and 3/8" ratchet.
• Torque the caliper slide bolts to 35 Nm (26 ft-lb) using the 3/8" torque wrench.
• Make sure the rubber boots are not twisted

Step 10: Reinstall the EPB Motor

• Carefully align the EPB motor with the drive on the back of the caliper.
• Install the EPB motor bolts using the Torx T30 or T40 bit and 3/8" ratchet.
• Snug the bolts and then torque to about 7 Nm (62 in-lb) with the 3/8" torque wrench if it reads in inch-pounds (or just snug, not very tight, if you don’t have in-lb).

Step 11: Repeat on the Other Rear Side

• Repeat Steps 2–10 on the other rear wheel.
• Always replace rear pads and rotors in pairs (both sides) for even braking.

Step 12: Reinstall Wheels and Lower the Vehicle

• Install each rear wheel and start all lug nuts by hand.
• Snug the lug nuts in a star pattern using the 19mm socket and 1/2" ratchet while the vehicle is still on jack stands.
• Use the floor jack to lift slightly, remove the jack stands, then lower the vehicle to the ground.
• Torque the lug nuts in a star pattern to 135 Nm (100 ft-lb) using the 1/2" torque wrench.

Step 13: Reconnect Battery and Settle the Brakes

• Reconnect the negative battery cable and tighten securely.
• Get in the driver’s seat and press the brake pedal slowly 10–15 times until it feels firm. This seats the pads against the rotors.
• Check the brake fluid level in the reservoir and adjust with DOT 4 brake fluid if needed (between MIN and MAX).

Step 14: Test the Electronic Parking Brake

• With the vehicle on level ground, turn the ignition on (engine running is fine).
• Apply and release the electronic parking brake a few times using the cabin switch.
• Listen for any abnormal noises from the rear brakes.
• If any EPB warning light stays on, cycle ignition off and on and ensure the connectors at the EPB motors are secure.

---

✅ After Repair

• Start the engine and gently press the brake pedal; it should feel firm, not spongy.
• Check around the rear calipers and hoses for any signs of fluid leaks.
• Perform a short, low-speed test drive in a safe area: make several gentle stops from 20–30 km/h to confirm smooth braking and no pulling or noise.
• Bed-in (break in) the new pads: make 8–10 medium stops from about 50–60 km/h down to 10–20 km/h, allowing a bit of cool-down between stops. Avoid hard panic stops for the first 200–300 km if possible.
• After the test drive, recheck wheel lug nut torque with the torque wrench.

---

💰 DIY vs Shop Cost

Shop Cost: $450–$700 (parts + labor for rear pads and rotors)

DIY Cost: $200–$350 (parts only, depending on brand)

You Save: $250–$350 by doing it yourself!

Shop labor rates typically run $100–$150/hour. This repair takes a shop approximately 1.5–2.0 hours.

---

🎯 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 above to add everything to your cart.