Change 1995 Ford Explorer Disc Brake Pads

Ford released the Explorer in the 1991 model year. This compact SUV became the replacement for the Ford Bronco II. The 1995 Ford Explorer was the first year of the second generation. The second generation brought about smoother body lines and a less truck-like look. The 1995 model came fitted with a 4.0-liter V-6 engine that produced 160 horsepower and 220 foot-pounds of torque. The 1995 Explorers brake system has two different styles of front brakes that are widely different from each other, in terms of brake pad replacement.

Instructions

Front Single Piston Brakes

1

Check the level of the fluid in the brake master cylinder and remove fluid, using a turkey baster, until the master cylinder is only halfway full. Transfer the removed fluid to a container.

2

Loosen the front lug nuts, with a ratchet and socket, but leave them loosely attached to the wheels.

3

Raise the front of the Explorer with a floor jack and place jack stands under the SUV's frame rails. Lower the Explorer until only the jack stands support its weight. Remove the lug nuts and pull the wheels from the vehicle.

4

Place an 8-inch C-clamp over the brake caliper so the screw portion touches the outer brake pad and the fixed part touches the inner part of the caliper body. Tighten the C-clamp to compress the internal caliper piston. Remove the C-clamp once the caliper stops moving.

5

Check the direction of the caliper bolt. If the head of the bolt is on the outside of the caliper, proceed to Step 6. If the nut is on the outside of the caliper, proceed directly to Step 7.

6

Tap the inner part of the upper bolt with a hammer until separation occurs between the bolt head and the metal sleeve. Cut off the head of the bolt with a hacksaw. Tap the tab on the outer part of the metal sleeve, known as the caliper pin, at a 45-degree angle with a hammer and flathead screwdriver until it slides into the hole in the caliper. Tap the caliper pin with a 1/2-inch punch until it falls out of the inner part of the caliper. Repeat this step for the bottom caliper bolt and pin.

7

Remove the nut from the upper caliper bolt with a ratchet and socket. Tap the caliper pin, the metal sleeve the bolt goes through, at a 45-degree angle with a hammer and flathead screwdriver until it slides into the hole in the caliper. Using a 1/2-inch punch and a hammer, tap the caliper pin until it falls from the inside part of the caliper.

8

Remove the caliper from the brake assembly and hang it from a nearby suspension component, using a bungee strap.

9

Remove the rotor by pulling it straight towards you and check the thickness of its disc with a micrometer in four places. Compare the thinnest measurement of the rotor to the discard specification stamped on the center of the rotor. Replace the rotor if it is thinner than the discard specification.

10

Check the rotor for any visual imperfections, such as: hot spotting, grooves or grinding. If these imperfections exist, compare the thinnest measurement of the rotor to the minimal machining measurement of 0.964 inches. If the rotor is thinner than that specification, replace it. If it is thicker than the minimal machining specification, have the rotor resurfaced by a professional. If the rotor has no imperfections, simply place the rotor back on the vehicle.

11

Remove the outer brake pad by prying the metal spring on the rear of the pad away from the caliper body and pulling the pad off of the caliper. Pull the inner brake pad from the steering knuckle, the metal assembly the caliper bolted to.

12

Pry the metal spring on the outer brake pad upward until you can easily push the brake pad onto the caliper body. Push the brake pad until the small metal buttons on the brake pad seats in the notches in the caliper.

13

Install the inner brake pad in the notches on the steering knuckle.

14

Remove the caliper from the bungee strap and place it over the brake rotor and the inner brake pad.

15

Apply a thin coat of disc brake grease to the new caliper pins and insert the new caliper bolts through the new caliper pins with the bolt head opposite of the tapered end of the caliper pins.

16

Slide the caliper pins into the holes in the caliper, with the tabs on the pins facing up on the top pin and down in the bottom pin, until the tabs on the inner part of the pin lock onto the inner part of the caliper body.

17

Tighten the caliper bolt nuts to 32 to 47 foot-pounds, using a torque wrench and socket, while holding the pin's head with a ratchet and torx bit socket.

18

Repeat steps 4 through 15 for the brake pads on the other side of the Explorer.

19

Place the wheels on the Explorer and hand-tighten the lug nuts. Lower the Explorer to the ground and tighten the lug nuts to 100 foot-pounds with a torque wrench and socket.

20

Check the fluid level in the master cylinder and add fluid from the small, clean container until the level reaches the "Max" line on the reservoir.

21

Press and release the brake pedal repeatedly until the pedal feels firm.

Dual Piston Front Brakes

22

Follow steps 1 through 4 in the "Front Single Piston Brakes" section.

23

Remove the two caliper slide pin bolts on the rear of the brake caliper with a ratchet and socket. Pull the caliper up and off of the brake rotor. Suspend the caliper from an available suspension component with a bungee strap.

24

Remove the brake caliper anchor plate bolts, with a ratchet and socket, and pull the anchor plate from the steering knuckle.

25

Follow Steps 9 through 11 in the "Front Single Piston Brakes" section to remove, check and install the rotor.

26

Reinstall the anchor plate on the Explorer and tighten its bolts to 100 foot-pounds, with a torque wrench and socket.

27

Insert the new brake pads into the caliper anchor plate and place the caliper over the brake pads. Tighten the caliper bolts to 14 to 26 foot-pounds with a torque wrench and socket.

28

Repeat steps 2 through 6 for the brake pads on the other side of the Explorer.

29

Follow steps 20 through 22 in the "Front Single Piston Brakes" section.

Rear Brake Pads

30

Check and remove brake fluid as instructed in step 1 of the "Front Single Piston Brakes" section.

31

Loosen the rear lug nut, with a ratchet and socket, but leave them loosely attached to the wheels.

32

Raise the rear of the Explorer with a floor jack and slide jack stands under the frame rails. Lower the jack until only the jack stands support the Explorers weight. Remove the rear lug nuts and the rear wheels.

33

Remove the two caliper slide bolts using a ratchet and socket. Pull the caliper up and off of the brake assembly. Support the caliper by hanging it from a nearby suspension component with a bungee strap.

34

Pry up on the metal retaining spring on the rear of the outer brake pad and slide the pad off of the caliper. Pry upward on the inner brake pad until the metal fingers are free from the caliper piston. Pull the brake pad from the caliper.

35

Follow steps 9 through 11 in the section titled "Front Single Piston Brakes" to inspect the rear rotors, using 0.439 inches as the minimal machining specification.

36

Install the inner brake pad on the caliper by guiding the metal finger on the rear of the pad into the caliper piston cavity until the fingers fully insert into the caliper piston. Pry up on the metal spring retainer on the rear of the outer brake pad and slid the pad onto the caliper's body. Press the pad until the spring fully seats on the caliper.

37

Place the caliper back on the anchor plate and tighten the caliper slide bolts to 20 foot-pounds with a torque wrench and socket.

38

Place the wheels on the rear of the Explorer and hand-tighten the lug nuts. Lower the Explorer to the ground and tighten the lug nuts to 100 foot-pounds with a torque wrench and socket.

39

Check the fluid level in the master cylinder and add fluid from the small, clean container until the level reaches the "Max" line on the reservoir.

40

Press and release the brake pedal repeatedly until the pedal feels firm.