How to Replace Front Rotors on the 2000 Explorer

The front brakes on the 2000 Ford Explorer provide the bulk of the vehicle's stopping power. Reliable braking depends on good brake pads and smooth, flat rotors. If your Explorer shudders, pulls to one side or makes strange noises while braking, it may be time to replace the rotors. Brake rotors are inexpensive and you can replace them in a driveway or garage using basic hand tools.

Instructions

Park the Explorer on a flat surface, preferably on concrete or asphalt. Engage the parking brake and securely chock the rear wheels. Loosen the lug nuts on the front wheel/tire assemblies with a lug wrench to make removal easier once the wheels are in the air. Jack up the front of the Explorer and support the vehicle using jack stands under the front cross member. Do not rely on the jack to support the vehicle during repairs.

Finish removing the lug nuts and remove the wheel/tire assemblies from the vehicle. Using the socket wrench or breaker bar, remove the two bolts holding the brake caliper to the anchor plate. Remove the brake caliper from the rotor and secure it out of the way with a piece of wire. Be careful not to kink or otherwise damage the brake line.

Continue the repair by following the steps in the section following that pertains to your vehicle. The preparation steps are the same for 4X4 and 4X2 Explorers, however, the steps for removing and replacing the brake rotors are significantly different.

Remove the brake caliper to free the brake rotor for removal. If the brake rotor does not pull off easily, spray penetrating oil around the threaded studs and in any areas where the rotor contacts the hub. Allow the penetrating oil to soak in for 20 minutes and then try to tap the rotor loose with the hammer. It may be necessary to repeat this step several times to remove a severely corroded rotor.

Clean the new rotor thoroughly with brake cleaner to remove any dirt and shipping oil. Align the holes in the new brake rotor with the threaded studs on the hub and push the rotor firmly onto the hub.

Place the caliper on the new rotor and reinstall the two mounting bolts through the anchor plate. Use the torque wrench to tighten the bolts to between 72 and 97 foot-pounds. Repeat steps 1 and 2 on the other front wheel. Align the holes in the front wheel/tire assemblies with the threaded studs on the hub and push the assembly onto the hub. Screw the lug nuts onto the threaded studs and tighten them to 100 foot-pounds. Raise the vehicle off the jack stands with the jack, remove the stands and lower the vehicle to the ground.

Remove the grease cap in the center of the rotor. Use pliers to remove the cotter pin from the nut retainer then remove the nut retainer. Use a socket wrench or breaker bar to remove the spindle nut located in the center of the rotor. Remove the outer wheel bearing washer and the outer bearing. Pull the brake rotor off the spindle. Remove the hub grease seal and inner wheel bearing from the back of the rotor.

Clean the wheel bearings thoroughly with brake cleaner and examine them for damage or excessive wear. Replace any bearings that appear damaged with new ones.

Coat the wheel bearings with high-temperature bearing grease; use the palm of your hand to work grease into all parts of the bearing. Install the inner bearing in the back of the new rotor and install a new grease seal to hold it in place. Slide the rotor onto the spindle and slide the outer bearing over the spindle and into the center of the rotor. Reinstall the outer bearing washer and spindle nut.

Use a torque wrench to tighten the spindle nut to between 17 and 24 foot-pounds while turning the brake rotor by hand. Continue turning the rotor and loosen the spindle nut until the rotor turns freely, then tighten the spindle nut to 17 inch-pounds. Place the nut retainer over the spindle nut and push the cotter pin through the hole in the spindle; bend the ends of the cotter pin back until they are flat against the spindle nut. Replace the hub grease cap. Thoroughly clean the rotor with brake cleaner to remove any dirt or shipping oil.