How to Replace the Front Brake Rotor on a 94 Ford Exp 4x4

The braking system on the Ford Explorer 4X4 makes use of hydraulics to slow and stop the vehicle. When you push the brake pedal with your foot, the master cylinder is activated, and it pushes fluid through the brake lines to the calipers. The brake calipers then squeeze the rotors between them and the friction causes the Explorer to slow down and stop. The friction causes the brakes and rotors to wear and when the rotors reach the minimum thickness of 0.810 inches, you must discard and replace them.

Instructions

1

Park the Ford Explorer on a level surface and turn off the key. Put the wheel chocks behind the rear tires of the vehicle. Lift the Explorer with the automobile jack. Place a jack stand under it close to the jacking point and raise it to the frame.

2

Remove the lug nuts from the wheel with the lug wrench and pull the tire from the Ford. Loosen the caliper bolts with a socket and ratchet. Pull the caliper from the mounting bracket and secure it to the strut with a wire tie. If you allow the caliper to hang, it will damage the brake hose.

3

Carefully pry the grease cap from the wheel hub using the screwdriver. Remove the cotter pin from the shaft using the pliers. Remove the locking nut using a wrench. Remove the adjusting nut using the wrench and then pull the flat washer from the shaft.

4

Remove the outer bearing cone and roller assembly from the hub. Be careful not to drop the bearings. Remove the hub and rotor assembly from the spindle.

5

Install the new rotor along with the hub assembly. Insert the roller assembly and the bearing cone. Pack the bearings with wheel grease. Slide the flat washer on the shaft. Install the adjusting nut and tighten it with a wrench. Install the lock nut and tighten it with a wrench. Install a new cotter pin and spread it open with the pliers.

6

Place some wheel grease over the assembly and carefully tap the grease cap into place with the rubber mallet. Cut the wire tie holding the caliper to the strut with the pliers. Place the caliper into the mounting cradle and tighten the locking pins with the socket and ratchet. Install the wheel on the Explorer and tighten the lug nuts with the lug wrench.

7

Remove the jack stand from under the Explorer and lower the vehicle to the ground. Repeat the procedure on the other wheel. Pump the brake several times when the project is complete to be sure that the brake pads bare resting on the rotors.

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