How Do I Replace Rotors on a 2002 Lincoln Navigator?

The 2002 Lincoln Navigator uses a hub assembly and composite rotor in the front brake system and a "Drum-In-Hat" style rear rotor that features a friction surface machined into the inside of the rotor hat area for a set of parking brake shoes to grip against. Replacing the rotors on this SUV is similar to other Ford trucks and SUVs of the same year. Special concern must be taken with the air bag suspension system to prevent damage to the air bags.

Instructions

Front Brakes

1

Turn the air ride system off by flipping the on/off switch located in the rear cargo area inside the right side storage compartment. Raise the front of the Navigator using a floor jack. Slide jack stands under the frame. Place wheel chocks to block the rear wheel on the opposite side of the front wheel you are working on. Remove the wheel.

2

Remove the caliper bolts that secure the caliper to the steering knuckle using a 15 mm socket and ratchet. Pry the caliper up using a large screwdriver and lift it off the rotor. Hang the caliper from the upper control arm to prevent damage to the brake hose. Slide the rotors off the hub assembly.

3

Clean rust or debris from the rotor mounting surface of the hub using sand paper. Slide the new rotors onto the hub. Secure the rotors with a lug nut to make caliper installation easier.

4

Reinstall the calipers over the new rotors. Tighten the 15 mm caliper bolts securely. Reinstall the front wheel. Repeat the process for the other side. Be sure to move the wheel chocks to the opposite side before removing the other front wheel. Turn the air bag switch to the "On" position when work is completed.

5

Raise the front of the Navigator high enough with the jack to remove the jack stands. Lower the vehicle to the ground. Remove the wheel chocks.

Rear Brakes

6

Block the front wheel using wheel chocks in the same manner as previously described. Position a floor jack under the rear differential and raise the rear wheels off the ground. Place jack stands under the rear control arm to support the Navigator. Remove the wheels.

7

Remove the two 13 mm caliper bolts using a 13 mm wrench. Pry the caliper up and lift it from the rear rotor. Hang it from the rear control arm to prevent damage to the brake hose.

8

Release the parking brake and slide the rotors off of the rear hub assembly and parking brake shoes. Clean the rotor mounting surface using sandpaper. Slide the new rotors onto the hub assembly and parking brake shoes.

9

Slip the caliper over the new rotor and secure it to the rear spindle with the two 13 mm bolts. Tighten the bolts securely with a 13 mm wrench.

10

Reinstall the rear wheels. Jack up the rear of the vehicle high enough to remove the jack stands. Lower the Navigator to the ground and retighten the wheels a final time. Turn the air suspension switch to the "On" position. Test drive the vehicle.