🔧 Expedition - Rear Brake Pad Replacement

This job replaces the rear brake pads on your Expedition. The rear brakes use an electric parking brake, so the parking brake system must be placed in service/maintenance mode before the caliper is removed.

Difficulty Level: Intermediate | Estimated Time: 1.5-2.5 hours

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⚠️ Safety & Precautions

• ⚠️ Do not remove the rear calipers until the electric parking brake is in maintenance mode.
• ⚠️ Work on level ground and support your Expedition with jack stands. Never rely on a jack alone.
• ⚠️ Brake dust is harmful. Do not blow it with compressed air; use brake cleaner and a rag.
• ⚠️ Brake fluid can damage paint. Keep the reservoir cap area clean and wipe spills immediately.
• ⚠️ Do not press the brake pedal while a caliper is removed.
• ⚠️ Battery disconnect is not normally required for rear pad replacement, but keep the ignition off after entering brake maintenance mode.

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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 lug nut socket
• 1/2-inch drive breaker bar
• 1/2-inch drive torque wrench
• 13mm socket
• 15mm wrench
• Ratchet
• Brake caliper piston compressor tool (specialty)
• Flathead screwdriver
• Wire brush
• Brake cleaner
• Shop rags
• Bungee cord
• Nitrile gloves
• Safety glasses

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Rear brake pad set - Qty: 1
• Rear brake hardware kit - Qty: 1
• Brake lubricant - Qty: 1
• Brake cleaner - Qty: 1

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📋 Before You Begin

• Park your Expedition on a flat surface.
• Place the transmission in Park.
• Release the parking brake before starting the maintenance mode sequence.
• Chock the front wheels with wheel chocks.
• Brake maintenance mode retracts the electric parking brake motors so the rear caliper pistons can be compressed safely.
• Check the brake fluid reservoir. If it is very full, remove a small amount with a clean suction tool before compressing the pistons.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Enter Rear Brake Maintenance Mode

• Sit in the driver seat and make sure the parking brake is released.
• Turn the ignition ON without starting the engine.
• Press and hold the accelerator pedal fully down.
• Press and hold the electric parking brake switch down in the release position.
• While holding both, turn the ignition OFF, then turn it back ON within about 5 seconds.
• Keep holding the accelerator pedal and parking brake switch until the instrument cluster shows maintenance mode or the rear parking brake motors finish cycling.
• Turn the ignition OFF.
• Listen for motor movement.

Step 2: Loosen the Rear Lug Nuts

• Use a 21mm lug nut socket and 1/2-inch drive breaker bar to loosen each rear lug nut about 1/2 turn.
• Do not remove the lug nuts yet.

Step 3: Raise and Support the Rear

• Use a floor jack rated 3-ton minimum at the rear lifting point to raise the rear of your Expedition.
• Place jack stands rated 3-ton minimum under solid rear support points.
• Lower the vehicle gently onto the jack stands.
• Give the vehicle a light push to confirm it is stable.

Step 4: Remove the Rear Wheels

• Use the 21mm lug nut socket and ratchet to remove the loosened lug nuts.
• Remove both rear wheels and set them flat on the ground.

Step 5: Remove the Rear Caliper Bolts

• Work on one side at a time so the other side can be used as a reference.
• Use a 15mm wrench to hold the caliper slide pin if it spins.
• Use a 13mm socket and ratchet to remove the upper and lower rear caliper guide pin bolts.
• A guide pin is the smooth sliding pin that lets the caliper move evenly as the pads wear.

Step 6: Lift Off and Support the Caliper

• Use a flathead screwdriver to gently pry the caliper outward if it is snug.
• Slide the caliper off the bracket.
• Support the caliper with a bungee cord.
• Do not let the caliper hang by the brake hose.

Step 7: Remove the Old Pads and Hardware

• Pull the old inner and outer brake pads out of the caliper bracket by hand.
• Use a flathead screwdriver to remove the old pad clips from the bracket.
• Pad clips are small metal guides that help the pads slide smoothly.
• Use brake cleaner and shop rags to clean the bracket area.
• Use a wire brush to clean rust from the pad contact areas.

Step 8: Compress the Caliper Piston

• Make sure the electric parking brake is still in maintenance mode.
• Use a brake caliper piston compressor tool to slowly press the caliper piston straight back into the caliper.
• A caliper piston is the round part that pushes the brake pad against the rotor.
• Compress slowly and watch the brake fluid level under the hood.
• Stop if the brake fluid reservoir gets too full.

Step 9: Install New Hardware and Pads

• Install the new rear brake pad clips by hand into the caliper bracket.
• Apply a thin layer of brake lubricant to the pad ears where they contact the clips.
• Do not put lubricant on the pad friction surface or rotor face.
• Install the new inner and outer rear brake pads into the bracket.
• Thin grease layer only.

Step 10: Reinstall the Rear Caliper

• Slide the caliper over the new pads.
• Use the 13mm socket and ratchet to install the caliper guide pin bolts.
• Use the 15mm wrench to hold the slide pin if needed.
• Torque to 35 Nm (26 ft-lbs).

Step 11: Repeat on the Other Side

• Repeat Steps 5 through 10 on the opposite rear brake.
• Use the same 13mm socket, 15mm wrench, flathead screwdriver, brake caliper piston compressor tool, wire brush, and brake cleaner.
• Rear brake pads should always be replaced in pairs.

Step 12: Reinstall the Rear Wheels

• Place each wheel back on the hub.
• Use the 21mm lug nut socket and ratchet to snug the lug nuts in a star pattern.
• Raise the vehicle slightly with the floor jack rated 3-ton minimum.
• Remove the jack stands rated 3-ton minimum.
• Lower your Expedition to the ground.
• Use the 1/2-inch drive torque wrench and 21mm lug nut socket to tighten the lug nuts.
• Torque to 204 Nm (150 ft-lbs).

Step 13: Exit Rear Brake Maintenance Mode

• Turn the ignition ON without starting the engine.
• Press and hold the accelerator pedal fully down.
• Pull and hold the electric parking brake switch up in the apply position.
• While holding both, turn the ignition OFF, then turn it back ON within about 5 seconds.
• Keep holding both until the instrument cluster exits maintenance mode or the rear parking brake motors finish cycling.
• Release the pedal and switch.

Step 14: Seat the Brake Pads

• Press the brake pedal several times until it feels firm.
• Use your foot only. Do not drive until the pedal firms up.
• Check the brake fluid level and top off only if needed with the correct brake fluid listed on the reservoir cap.

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✅ After Repair

• Start your Expedition and confirm the brake warning light turns off.
• Apply and release the electric parking brake several times to confirm normal operation.
• Test drive slowly in a safe area and verify the brake pedal feels firm.
• Perform a gentle break-in: make several smooth stops from moderate speed, avoiding hard braking for the first 100-200 miles.
• Recheck lug nut torque after the first short drive: Torque to 204 Nm (150 ft-lbs).

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💰 DIY vs Shop Cost

Shop Cost: $300-$550 (parts + labor)

DIY Cost: $60-$160 (parts only)

You Save: $240-$390 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 1.0-1.5 hours.

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