🔧 Expedition - Rear Brake Pads & Rotor Replacement

This job replaces the rear brake pads and rotors on your Expedition. Because your Expedition uses an Electronic Parking Brake (EPB), you must put the EPB into “service/maintenance mode” before compressing the rear caliper pistons.

Difficulty Level: Intermediate | Estimated Time: 2.0-3.5 hours

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⚠️ Safety & Precautions

• ⚠️ Support the SUV with jack stands; never rely on a jack.
• ⚠️ EPB-equipped rear calipers can be damaged if you force the piston without EPB service mode.
• ⚠️ Brakes contain dust; avoid compressed air and wear a mask.
• ⚠️ Work on one side at a time so you can reference the other side.
• ⚠️ If you open the brake fluid reservoir, keep dirt out and don’t overfill.

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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
• Safety glasses
• Nitrile gloves
• Lug nut socket (21mm)
• Breaker bar (1/2")
• Torque wrench (30-250 ft-lbs range)
• Socket set (metric, 3/8" and 1/2")
• Ratchet (3/8")
• Ratchet (1/2")
• Caliper hanger hook
• Large C-clamp
• Flat blade screwdriver
• Wire brush
• Brake cleaner spray
• Scan tool with Ford EPB service mode (specialty)

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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 (clips/shims) - Qty: 1
• Brake caliper slide pin boots (if torn) - Qty: 1
• High-temp silicone brake grease - Qty: 1
• Brake fluid (DOT 4 LV) - Qty: 1 quart

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📋 Before You Begin

• Park on level ground, set the transmission to Park, and chock the front wheels.
• Make sure the EPB is released before lifting.
• Plan to use a scan tool to command the EPB into service mode (this retracts the EPB motors).
• Loosen the rear lug nuts slightly before lifting using a 21mm socket and breaker bar.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Put the EPB into service/maintenance mode

• Connect your scan tool with Ford EPB service mode (specialty) to the OBD-II port.
• Use the scan tool function for EPB Service Mode (wording varies by tool) and command both rear calipers to retract.
• If your tool fails, stop and don’t compress.

Step 2: Lift the rear and remove the wheels

• Lift the rear safely with a floor jack (rated 3-ton minimum) and support with jack stands (rated 3-ton minimum).
• Remove the rear wheels using a 21mm socket and ratchet (1/2").
• During reassembly: Torque lug nuts to 203 Nm (150 ft-lbs) using a torque wrench (30-250 ft-lbs range).

Step 3: Remove the rear caliper

• Turn the steering wheel is not applicable for rear; position yourself for access.
• Remove the caliper guide/slide pin bolts using your socket set (metric, 3/8" and 1/2") and ratchet (3/8").
• Lift the caliper off the bracket and hang it with a caliper hanger hook (do not let it hang by the hose).
• During reassembly: Torque caliper slide pin bolts to 35 Nm (26 ft-lbs) using a torque wrench (30-250 ft-lbs range).

Step 4: Remove the old pads and hardware

• Remove the pads from the bracket by hand; use a flat blade screwdriver gently if they’re stuck.
• Remove the stainless hardware clips from the bracket using a flat blade screwdriver.
• Clean pad contact points on the bracket with a wire brush and brake cleaner spray.

Step 5: Remove the caliper bracket and rotor

• Remove the caliper bracket bolts using a socket set (metric, 3/8" and 1/2") and breaker bar (1/2").
• Remove the bracket and set it aside.
• Pull the rotor straight off the hub; if stuck, spray the hub/rotor center with brake cleaner spray and tap the rotor hat lightly (use the breaker bar (1/2") handle as a non-marring persuader).
• During reassembly: Torque rear caliper bracket bolts to 250 Nm (184 ft-lbs) using a torque wrench (30-250 ft-lbs range).

Step 6: Prep the hub and install the new rotor

• Clean the hub face with a wire brush and brake cleaner spray so the new rotor sits flat.
• Install the new rotor onto the hub.
• Hold the rotor in place temporarily by reinstalling 1-2 lug nuts hand-tight (use the 21mm socket and ratchet (1/2") lightly).

Step 7: Install new hardware and pads

• Install the new hardware clips onto the bracket by hand.
• Apply a thin film of high-temp silicone brake grease to the pad “ears” where they slide on the clips. (Don’t get grease on pad friction material.)
• Install the new pads into the bracket.

Step 8: Compress the rear caliper piston (EPB already in service mode)

• Open the hood and check the brake fluid reservoir level (do not overfill later).
• Use a large C-clamp to slowly compress the caliper piston straight back into the caliper.
• Go slow to avoid fluid overflow.

Step 9: Reinstall the caliper and repeat on the other side

• Reinstall the caliper over the new pads and start the bolts by hand.
• Tighten the slide pin bolts using a socket set (metric, 3/8" and 1/2") and ratchet (3/8"), then torque to 35 Nm (26 ft-lbs) with a torque wrench (30-250 ft-lbs range).
• Repeat Steps 3-9 on the other rear wheel.

Step 10: Exit EPB service mode

• Use the scan tool with Ford EPB service mode (specialty) to command the EPB out of service mode.
• Cycle the EPB on and off once with the cabin switch to confirm normal operation.

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✅ After Repair

• Press the brake pedal slowly 10-15 times before driving until it feels firm.
• Check the brake fluid level and top off with DOT 4 LV only if needed.
• Do a low-speed test in a safe area: forward/reverse braking, then confirm EPB hold works.
• Bed-in the pads: perform several gentle stops from 30-40 mph, allowing cool-down between stops.
• If you have warning lights, scan for codes using the scan tool with Ford EPB service mode (specialty).

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💰 DIY vs Shop Cost

Shop Cost: $650-$1,050 (parts + labor)

DIY Cost: $220-$450 (parts only)

You Save: $430-$600 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 2.0-3.0 hours.

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🎯 Ready to get started?

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