🔧 Front Brakes & Rotors - Replacement

This job replaces the front brake pads and rotors on your Explorer. The old rotors are removed, new rotors are installed, and the calipers are serviced so the new pads can seat correctly.

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

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⚠️ Safety & Precautions

• Work on a flat surface and chock the rear wheels before lifting the front.
• Use jack stands; never rely on a floor jack alone.
• Brake dust can be harmful. Do not blow it off with compressed air.
• Support each caliper with a hanger or wire so the brake hose is not stretched.
• Do not press the brake pedal with a caliper removed.
• If your Explorer has any brake wear warning or ABS issues, scan for codes after the repair.

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🔧 Required Tools

You'll need the following tools for this repair:

• Floor jack (rated 3-ton minimum)
• Jack stands (rated for vehicle weight)
• Wheel chocks
• 19mm lug wrench or socket
• 13mm socket
• 18mm socket
• Ratchet
• Breaker bar
• Torque wrench
• C-clamp or brake caliper compression tool (specialty)
• Brake caliper hanger or sturdy wire
• Flat screwdriver
• Wire brush
• Brake cleaner
• Micrometer or caliper gauge
• Safety glasses
• Nitrile gloves

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Front brake pad set - Qty: 1
• Front brake rotors - Replace in pairs - Qty: 2
• Brake hardware kit - Qty: 1
• Brake cleaner - Qty: 1
• High-temperature brake grease - Qty: 1

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📋 Before You Begin

• Park on level ground, set the parking brake, and chock the rear wheels.
• Loosen the front lug nuts before lifting the vehicle.
• If the brake pedal feels soft before starting, do not drive the vehicle until the repair is finished.
• Assumption: standard front disc brake setup with bolt sizes commonly used on this platform.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Raise the front of the vehicle

• Use the floor jack to lift the front of the Explorer at the proper front jacking point.
• Place jack stands under the front support points and lower the vehicle onto them.
• Remove the front wheels with the 19mm lug wrench or socket.

Step 2: Remove the brake caliper

• Use the 13mm socket and ratchet to remove the caliper slide pin bolts.
• Lift the caliper off the bracket carefully.
• Hang the caliper with a brake caliper hanger or sturdy wire.
• Do not let the hose carry the weight.

Step 3: Remove the caliper bracket

• Use the 18mm socket and breaker bar to remove the caliper bracket bolts.
• Remove the bracket from the knuckle and set it aside.

Step 4: Remove the rotor

• Pull the rotor straight off the hub.
• If it is stuck, use a flat screwdriver through the rotor access hole or tap the rotor hat gently with a rubber mallet.
• Clean the hub face with a wire brush and brake cleaner.

Step 5: Install the new rotor

• Spray the new rotor with brake cleaner to remove protective oil, then wipe it dry.
• Install the new rotor on the hub.
• If the rotor uses a retaining screw on your Explorer, remove it with the correct small driver before rotor removal and reinstall only if needed.

Step 6: Service the caliper bracket and pads

• Remove the old pads from the bracket.
• Clean the pad lands and slide points with a wire brush.
• Install the new hardware from the brake hardware kit if included.
• Apply a thin coat of high-temperature brake grease to the pad contact points and slide surfaces.

Step 7: Compress the caliper piston

• Use a C-clamp or brake caliper compression tool to slowly push the piston back into the caliper.
• Watch the brake fluid level in the reservoir so it does not overflow.
• Compress slowly and evenly.

Step 8: Reinstall the bracket, pads, and caliper

• Install the caliper bracket and tighten the bolts with the 18mm socket.
• Torque to 175 Nm (129 ft-lbs).
• Install the new pads into the bracket.
• Reinstall the caliper over the pads and tighten the slide pin bolts with the 13mm socket.
• Torque to 35 Nm (26 ft-lbs).

Step 9: Reinstall wheels and lower the vehicle

• Reinstall the front wheels and hand-tighten the lug nuts with the 19mm lug wrench or socket.
• Lower the vehicle with the floor jack.
• Torque to 150 Nm (111 ft-lbs) on the lug nuts in a star pattern.

Step 10: Settle the pads

• Before moving the vehicle, pump the brake pedal slowly until it becomes firm.
• This seats the caliper piston against the new pads and rotors.

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✅ After Repair

• Check the brake fluid level and top off only if needed.
• Start the vehicle and make sure the brake warning lights are off.
• Test the brakes at very low speed first.
• For the first 200-300 miles, avoid hard stops unless needed.
• If you hear grinding, feel pulsation, or get a brake warning light, inspect your work right away.

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💰 DIY vs Shop Cost

Shop Cost: $450-$850 (parts + labor)

DIY Cost: $140-$320 (parts only)

You Save: $310-$530 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 1.5-2.5 hours.

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🎯 Ready to get started?

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