How to Change the Brake Pads on a 1999 Ford Windstar

The 1999 Ford Windstar featured front disc brakes on the front-wheel drive minivan. The rear brakes were most commonly rear drum brakes, but there were also models made with rear disc brakes. Disc brakes use brake pads and rotors, whereas rear drum brakes use brake shoes and brake drums. While disc brakes are always featured in the front braking system, rear disc brakes are slightly superior to rear drum brakes in performance, but can require more replacement than rear drum brakes.

Instructions

1

Park the Windstar on a flat surface which would be suitable for lifting and supporting the vehicle safely and then open the hood.

2

Use a brake fluid suction device to remove 1/2 of the brake fluid from the master cylinder reservoir and then discard the fluid. Replace the cover to the master cylinder reservoir.

3

Place a wheel block against one of the tires on the opposite axle of which you're going to be replacing brake pads on. Make sure the vehicle is in park and only apply the parking brake if you're replacing the front brake pads. The parking brake applied will not allow you to remove the rear calipers if you're replacing rear brake pads.

4

Break the lug nuts loose on the two tires of the same axle you're replacing the brake pads on using the tire iron. Only turn the lug nuts 1/4 turn counterclockwise to break them loose.

5

Lift the axle of the Windstar--one side at a time--using the jack and then support the vehicle onto jack stands in a safe and secure manner.

6

Remove the lug nuts and then remove the wheels.

7

Remove the guide pin bolts on the front calipers or the caliper bolts on the rear calipers using a suitable box-end wrench.

8

Use the small pry tool to gently pry the caliper off of the rotor and knuckle assembly and the use a length of wire to tie the caliper onto the coil spring to support it.

9

Use the C-clamp to compress the piston of the caliper fully into the caliper bore.

10

Remove the brake pads from the anchor plate. Use the small pry tool if necessary. Remove the slippers on the anchor plate abutments on the rear disc brakes. These should be replaced and supplied in the box of the replacement brake pad set.

11

Inspect the rotors for any rust pits, hot spots or surface cracks. Any of these symptoms present on the surface of the rotor should require replacement of the component. If not, use the sand paper to remove the glazing surface on the surface of both sides of the rotor.

12

Place silicone brake lubricant on the front brake pad insulators or the rear replacement slippers after reinstalling them on the anchor plate abutments.

13

Place the new pads into the anchor plates. Be sure to align the notches on the rear pads backing plates appropriately.

14

Replace the caliper over the rotor and pads assembly and align the guide pin bolts or the caliper bolts back into the calipers. Tighten the front caliper guide bolts to 38-foot lbs. with the torque wrench and a socket. Tighten the rear caliper bolts to 14-foot lbs. with the torque wrench and a socket. Repeat this procedure for the opposite side of the same axle.

15

Replace the wheels and lug nuts and tighten the lug nuts so they are snug to the hub of each wheel. Slowly lower the vehicle using the jack to remove the jack stands and then torque the lug nuts in a star pattern to 100-foot lbs. with the torque wrench and a socket.

16

Pump the foot brake pedal several times to seat the pads to the rotors and extend the brake caliper pistons. Recheck the brake fluid level in the master cylinder reservoir and add only new brake fluid to the full mark if necessary. Replace the cap to the master cylinder reservoir and test drive the Windstar.