🔧 Expedition - Rear Brake Pad & Rotor Replacement

This repair replaces the rear brake pads and rear brake rotors on your Expedition. The rear brakes use an electric parking brake, so the system must be placed into brake maintenance mode before pushing the caliper piston back.

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

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⚠️ Safety & Precautions

• ⚠️ Do not remove the rear calipers until the electric parking brake is in maintenance mode.
• ⚠️ Support your Expedition with jack stands. Never work under a vehicle supported only by a jack.
• ⚠️ Brake dust can irritate your lungs. Do not blow it with compressed air.
• ⚠️ Brake fluid damages paint. Wipe spills immediately with water.
• ⚠️ The rear caliper piston must be compressed straight in after parking brake maintenance mode is active.
• ⚠️ Do not press the brake pedal while the caliper is removed.
• ⚠️ Battery disconnect is not required for this 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 3-ton minimum
• Wheel chocks
• 22mm lug nut socket
• 1/2-inch drive breaker bar
• 1/2-inch drive torque wrench 50-250 ft-lbs
• 3/8-inch drive ratchet
• 13mm socket
• 18mm socket
• 18mm wrench
• 6-inch C-clamp
• Disc brake piston compressor tool
• Brake caliper hanger hook
• Flat blade screwdriver
• Dead blow hammer
• Wire brush
• Brake parts cleaning brush
• Brake cleaner spray nozzle
• Catch pan
• 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 - Qty: 1
• Brake cleaner - Qty: 2 cans
• High-temperature brake grease - Qty: 1
• DOT 4 brake fluid - Qty: 1 pint

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📋 Before You Begin

• 🅿️ Park your Expedition on level ground.
• 🧱 Place wheel chocks in front of the front tires.
• 🔓 Leave the parking brake released before entering maintenance mode.
• 🚪 Close all doors before using the parking brake maintenance mode sequence.
• 🧰 A torque wrench tightens bolts correctly. This is important for brake safety.
• 🧴 Open the hood and check the brake fluid reservoir. If it is completely full, remove a small amount with a clean suction tool before compressing the calipers.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Put the Electric Parking Brake in Maintenance Mode

• Use your foot to press and hold the accelerator pedal fully down.
• Press and hold the parking brake switch down in the release direction.
• While holding both, turn the ignition ON without starting the engine.
• Continue holding until the instrument cluster shows the parking brake is in maintenance mode or the rear parking brake motors finish moving.
• Turn the ignition OFF.
• Listen for both rear motors.

Step 2: Loosen the Rear Lug Nuts

• Use a 22mm lug nut socket and 1/2-inch drive breaker bar to loosen each rear lug nut about half a turn.
• Do this while the tires are still on the ground so the wheels do not spin.

Step 3: Lift and Support the Rear of the Vehicle

• Use a floor jack rated 3-ton minimum at the rear center jacking point or approved rear frame lift point.
• Place jack stands rated 3-ton minimum under the rear frame support points.
• Lower your Expedition gently onto the jack stands.
• Give the vehicle a light push to confirm it is stable.

Step 4: Remove the Rear Wheels

• Use the 22mm lug nut socket and 3/8-inch drive ratchet to remove the loosened lug nuts.
• Remove both rear wheels and set them flat on the ground.

Step 5: Remove the Rear Brake Caliper

• Put on safety glasses, nitrile gloves, and a dust mask.
• Use a 13mm socket to remove the two rear caliper slide pin bolts.
• If the slide pin spins, hold it with an 18mm wrench while removing the bolt with the 13mm socket.
• Lift the caliper off the bracket.
• Hang the caliper with a brake caliper hanger hook from the suspension.
• Do not let the caliper hang by the rubber brake hose.

Step 6: Remove the Old Brake Pads and Hardware

• Use a flat blade screwdriver to gently pry the old pads out of the caliper bracket.
• Use the flat blade screwdriver to remove the old stainless pad clips from the bracket.
• Brake hardware means the small metal clips that let the pads slide smoothly.

Step 7: Remove the Rear Caliper Bracket

• Use an 18mm socket and 1/2-inch drive breaker bar to remove the two caliper bracket bolts.
• Remove the caliper bracket and set it on a clean surface.

Step 8: Remove the Rear Rotor

• Pull the rotor straight off the hub by hand.
• If it is stuck, tap the rotor hat area with a dead blow hammer.
• Do not hit the wheel studs.
• If rust is heavy, spray the hub area with brake cleaner spray nozzle and let it soak briefly.

Step 9: Clean the Hub and Bracket

• Use a wire brush to clean rust from the wheel hub face.
• Use a brake parts cleaning brush and brake cleaner spray nozzle to clean the caliper bracket pad lands.
• The pad lands are the small bracket surfaces where the pad clips sit.
• Place a catch pan under the area while spraying brake cleaner.
• Clean metal prevents brake pulsation.

Step 10: Install the New Rotor

• Clean both sides of the new rotor with brake cleaner spray nozzle to remove protective oil.
• Slide the new rotor onto the hub by hand.
• Install one lug nut by hand to hold the rotor flat while you work.

Step 11: Reinstall the Caliper Bracket

• Position the caliper bracket over the rotor.
• Start both bracket bolts by hand to avoid cross-threading.
• Use the 18mm socket and 1/2-inch drive torque wrench to tighten the caliper bracket bolts.
• Torque to 184 Nm (136 ft-lbs)

Step 12: Install New Brake Hardware and Pads

• Press the new pad clips into the caliper bracket by hand.
• Apply a thin layer of high-temperature brake grease to the pad contact points on the clips.
• Do not get grease on the rotor or pad friction material.
• Install the inner and outer rear brake pads into the bracket by hand.
• The friction material faces the rotor.

Step 13: Compress the Rear Caliper Piston

• Use a disc brake piston compressor tool or 6-inch C-clamp to slowly push the caliper piston straight back into the caliper.
• Watch the brake fluid reservoir while compressing the piston.
• If the fluid rises too high, remove a small amount of DOT 4 brake fluid from the reservoir with a clean suction tool.
• Do not twist the piston on this electric parking brake caliper.

Step 14: Reinstall the Rear Caliper

• Slide the caliper over the new pads and rotor.
• Install the caliper slide pin bolts by hand.
• Use a 13mm socket and 3/8-inch drive torque wrench to tighten the slide pin bolts.
• Torque to 35 Nm (26 ft-lbs)

Step 15: Repeat on the Other Rear Side

• Use the same tools and steps on the opposite rear brake.
• Always replace rear pads and rotors in pairs.

Step 16: Reinstall the Rear Wheels

• Remove the temporary lug nut holding each rotor.
• Install the rear wheels by hand.
• Use the 22mm lug nut socket to snug the lug nuts in a star pattern.
• Use the floor jack rated 3-ton minimum to lift slightly, remove the jack stands, and lower your Expedition to the ground.
• Use the 22mm lug nut socket and 1/2-inch drive torque wrench to tighten the lug nuts in a star pattern.
• Torque to 204 Nm (150 ft-lbs)

Step 17: Exit Electric Parking Brake Maintenance Mode

• Turn the ignition ON without starting the engine.
• Press and hold the accelerator pedal fully down.
• Pull and hold the parking brake switch up in the apply direction.
• Continue holding until the rear parking brake motors run and the maintenance mode message clears.
• Turn the ignition OFF.

Step 18: Restore Brake Pedal Pressure

• Press the brake pedal slowly several times until it feels firm.
• Use your eyes to check the brake fluid level in the reservoir.
• Add DOT 4 brake fluid only if the level is below the correct mark.

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✅ After Repair

• ✅ Start your Expedition and confirm the brake warning light is off.
• ✅ Apply and release the parking brake several times to confirm normal operation.
• ✅ Check around both rear calipers for fluid leaks.
• ✅ Test drive at low speed first and confirm the brake pedal feels firm.
• ✅ Bed in the new pads with 8-10 moderate stops from about 30-40 mph, allowing a short cool-down between stops.
• ✅ Avoid hard panic stops for the first 200 miles unless needed for safety.
• ✅ Recheck lug nut torque after the first short drive.

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💰 DIY vs Shop Cost

Shop Cost: $450-$750 (parts + labor)

DIY Cost: $180-$350 (parts only)

You Save: $270-$400 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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