🔧 Express - Rear Brake Pads & Rotor Replacement

You’ll remove the rear wheels, take off the calipers and brackets, replace the brake pads and rotors, then reassemble everything with the correct torque. On your Express, the rear rotor may also contain a small “drum-in-hat” parking brake inside, so the parking brake must be released to remove the rotor.

Assumption: Rear disc brakes with a drum-in-hat mechanical parking brake (common on Express 3500).

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

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⚠️ Safety & Precautions

• ⚠️ Work on level ground and chock the front wheels.
• ⚠️ Support the van with jack stands; never rely on a floor jack alone.
• ⚠️ Release the parking brake before removing rear rotors (parking brake shoes can lock the rotor on).
• ⚠️ Don’t breathe brake dust; use brake cleaner and wear a mask.
• ⚠️ Do not let the caliper hang by the brake hose; support it with a hanger.
• ⚠️ Brake fluid can damage paint; wipe spills immediately.

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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
• 21mm socket
• 1/2" drive breaker bar
• 1/2" drive torque wrench (30-250 ft-lbs range)
• 13mm socket
• 18mm socket
• Ratchet
• Socket extension (6")
• C-clamp (6")
• Brake caliper hanger hook
• Flathead screwdriver
• Dead-blow hammer
• M8 x 1.25 bolts (pair, 25-40mm long)
• Wire brush
• Micrometer or vernier caliper (measuring tool)
• Brake parts cleaner
• Shop towels
• Disposable nitrile gloves
• Safety glasses
• Dust mask

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Rear brake pad set - Qty: 1
• Rear brake rotors - Qty: 2
• Rear brake hardware kit (abutment clips) - Qty: 1
• Brake caliper slide pin grease (high-temp silicone) - Qty: 1
• Brake cleaner - Qty: 1-2 cans
• DOT 3 brake fluid - Qty: 1 quart
• Anti-seize compound - Qty: 1
• Rear parking brake shoes (optional, if worn/contaminated) - Qty: 1 set
• Rear parking brake hardware kit (optional, if springs/rusty) - Qty: 1

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📋 Before You Begin

• 🧰 Park on level ground, shift to Park, and chock both front wheels.
• 🧰 Release the parking brake fully (foot pedal must be up).
• 🧰 Loosen the rear lug nuts 1/2 turn before lifting (use 21mm socket and breaker bar).
• 🧰 Lift the rear and support the axle securely on jack stands; keep the floor jack lightly supporting.
• 🧰 Open the hood and locate the brake fluid reservoir; make sure it isn’t overfull (fluid rises when you compress pistons).

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Remove the rear wheels

• Use a 21mm socket to remove all lug nuts, then remove the wheel.
• Torque to 190 Nm (140 ft-lbs) when reinstalling lug nuts later.

Step 2: Remove the rear brake caliper

• Turn the steering is fixed (rear), so position your body for access and good leverage.
• Use a 13mm socket and ratchet to remove the caliper guide/slide pin bolts.
• Lift the caliper off the bracket and hang it using a brake caliper hanger hook.
• Never let the caliper dangle by the hose.

Step 3: Remove the pads and hardware

• Pull the old pads out of the bracket by hand.
• Use a flathead screwdriver to remove the stainless pad clips (abutment clips) from the bracket.
• Clean the bracket pad lands (where clips sit) using a wire brush and brake parts cleaner.

Step 4: Remove the caliper bracket

• Use an 18mm socket, breaker bar, and socket extension (6") to remove the two caliper bracket bolts.
• Set the bracket aside on a towel.
• Torque to 221 Nm (163 ft-lbs) when reinstalling the caliper bracket bolts.

Step 5: Remove the rotor (and deal with the parking brake if it’s stuck)

• If the rotor slides off, remove it by hand.
• If it’s stuck to the hub, spray the hub-to-rotor center area with brake parts cleaner, then strike the rotor hat with a dead-blow hammer to break rust loose.
• If your rotor has threaded “jacking” holes, thread in two M8 x 1.25 bolts evenly to push the rotor off.
• If the rotor won’t come off because of the parking brake shoes inside:
  • Make sure the parking brake is fully released.
  • Use a flathead screwdriver to turn the parking brake star adjuster (through the access slot if equipped) to retract the shoes until the rotor comes off.
  • Small turns—check often.

Step 6: Prep the hub and install the new rotor

• Use a wire brush to clean rust off the hub face so the new rotor sits flat.
• Apply a very thin film of anti-seize compound to the hub center (avoid the wheel studs and braking surfaces).
• Clean the new rotor braking surfaces with brake parts cleaner and shop towels (rotors ship with protective oil).
• Install the new rotor onto the hub.

Step 7: Service the slide pins and reinstall the bracket

• Pull the slide pins out of the bracket by hand (they’re the smooth pins the caliper moves on).
• Wipe them clean with shop towels, then apply a thin coat of brake caliper slide pin grease (high-temp silicone).
• Reinstall slide pins and make sure the rubber boots seat all the way around.
• Reinstall the caliper bracket using the 18mm socket, then torque to 221 Nm (163 ft-lbs).

Step 8: Install new pad hardware and pads

• Snap the new abutment clips from the rear brake hardware kit into the bracket.
• Apply a tiny amount of brake caliper slide pin grease (high-temp silicone) where the pad ears touch the clips (not on rotor).
• Install the new pads into the bracket.

Step 9: Compress the caliper piston and reinstall the caliper

• Place an old pad against the caliper piston face, then use a C-clamp (6") to slowly push the piston back in.
• C-clamp note: This tool squeezes the piston back so thicker new pads fit.
• Reinstall the caliper over the pads.
• Install the guide/slide pin bolts using a 13mm socket.
• Torque to 31 Nm (23 ft-lbs) for the caliper guide/slide pin bolts.

Step 10: Repeat on the other rear wheel

• Do the same pad and rotor replacement on the opposite side.
• Always replace pads and rotors in pairs.

Step 11: Reinstall wheels and lower the van

• Reinstall wheels and hand-start all lug nuts.
• Lower the van until the tires just touch the ground, then use a torque wrench and 21mm socket to tighten lug nuts in a star pattern.
• Torque to 190 Nm (140 ft-lbs).

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✅ After Repair

• 🧪 Pump the brake pedal slowly 10-15 times until it feels firm (this seats the pistons to the new pads).
• 🧪 Check brake fluid level and top off with DOT 3 brake fluid if needed (do not overfill).
• 🧪 Test the parking brake holds the van; if it feels weak, the parking brake may need adjustment.
• 🧪 Road test at low speed first; verify no pulling, grinding, or warning lights.
• 🧪 Pad bed-in (break-in): make 8-10 moderate stops from 30-40 mph, letting brakes cool slightly between stops.

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💰 DIY vs Shop Cost

Shop Cost: $600-$1,100 (parts + labor)

DIY Cost: $180-$450 (parts only)

You Save: $420-$650 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?

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