How to Replace the Brake Pads on a Windstar

The brake pads on a Ford Windstar use a brake caliper and rotor design. Over time, the brake pads wear down due to the friction generated by the intense clamping forces of the brake caliper. When the pad material is 1/8-inch thick, you need to replace the brakes before you damage the caliper or the rotor.

Instructions

1

Break the lug nuts loose on the front wheels with a tire wrench. These can sometimes be a little tough since they are torqued to 100 foot pounds, which is why you need to loosen them now. It will be practically impossible once the wheels are off the ground. Loosen the lugs counterclockwise, but only turn then 30 degrees. Do not unseat the wheel from the wheel hub or you will damage the vehicle and possibly hurt yourself since the full weight of the vehicle is still on the wheels.

2

Raise the Windstar onto jack stands. Lift the Windstar up using the the front jack point located behind the radiator. Place jack stands under the frame of the vehicle or under the front pinch welds on either side of the vehicle and lower the Windstar onto the pinch welds.

3

Remove the wheel lug nuts and pull the wheel off the wheel hub.

4

Remove the caliper pin bolt on the bottom of the caliper.

5

Secure the C-clamp to the caliper assembly. The screw end of the clamp should be flat against the back of the outboard brake pad while the other end of the clamp sits flush with the back of the caliper. Turn the handle on the clamp clockwise to force the caliper piston back into the caliper assembly.

6

Remove the caliper mounting bolts, slide the caliper off the brake rotor and secure the caliper to the coil springs above the wheel hub.

7

Open caliper bracket up from the bottom and pull the old brake pads out.

8

Install the new brake pads and reassemble the caliper. Torque the caliper mounting bolts to 55 foot pounds with a torque wrench.

9

Spray the brake assembly down with brake parts cleaner.

10

Put the wheel back on and tighten the lug nuts.

11

Lower the Windstar to the ground and torque the lug nuts to 100 foot pounds with a torque wrench.