How to Replace Brakes on a 1991 Ford Aerostar

The Ford Aerostar, first introduced in the 1986 model year, was the Automakers attempt to compete with Dodge's Caravan. The first edition of the Aerostar had an underpowered 2.3-liter in-line four-cylinder. The 1991 Aerostar, on year before a mild redesigns, was fitted with either a 3-liter V-6 or a 4-liter V-6, making the van much more powerful than before. The front brakes on the Aerostar are basic disc brakes. Replacing the front brake pads on the Aerostar is slightly different than other vehicles as the caliper is help by pins, as opposed to bolts.

Instructions

Loosen the Aerostar's front lug nuts, do not remove the lug nuts.

Raise the front of the vehicle, using the floor jack. Place the jack stands beneath the vehicles, ideally under the rails of the frame. Lower the jack, allowing the vehicle to rest on the stands.

Continue loosening the lug nuts and remove them from the front wheels. Pull the front wheels from the van.

Place the C-clamp over the brake caliper, so the fixed part of the clamp is contacting the rear of the caliper and the screw part is contacting the outer brake pad.

Tighten the C-clamp until it can no longer tighten. This action compresses the caliper's internal piston, allowing the clearance needed for the new, thicker brake pads.

Look where the caliper connects to the spindle, the component the connects the wheel assembly to the vehicle, and locate the pins holding the caliper to the spindle. There are two pins, one upper and one lower.

Place the center punch on the outer portion of the lower caliper pin and lightly tap the punch, at a 45- degree angle, with a hammer, this compresses the locking tab. Once the tab is compressed place the punch in a direct line with the pin and tap it until the pin fall out of the rear side of the caliper. Repeat this step for the second pin on the caliper.

Lift the caliper off of the spindle. Notice the brake pads remain attached to the caliper.

Attach the caliper to a suspension component, using the bungee strap. Never allow the caliper to hang by its rubber hose, as damage may occur.

Place the screwdriver under the anti-rattle clip, small metal clip, at the lower end of the inner brake pad. Compress the clip by prying with the screwdriver and remove the inner pad. Make note of how the pad is positioned before removal, as the new pad must be positioned the same way.

Place the flathead screw driver beneath the metal clip on the rear of the outer pad and lightly pry upward to release the clip. Slide the torque buttons, small, metal tabs on either end of the pad, from the notches in the caliper and pull the pad from the caliper.

Place the new inner brake pad into the notch at the lower portion of the caliper, anti-rattle clip first, press downward on the pad to compress the clips, then slide the upper portion of the pad into the upper notch in the caliper.

Place the outer pad on the rotor by pressing it until the torque button are seated into the notches in the caliper.

Place the caliper back on the spindle.

Apply a coat of brake grease to the caliper pins. Place the lower pin between the caliper and the groove in the spindle, make certain to position the tabs so they will seat against the spindle. Lightly tap the pin, with the hammer, until the tabs seat against the spindle. Repeat this step for the upper caliper pin.

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

Place the front wheels back on the van and hand-tighten the lug nuts.

Raise the Aerostar off of the jack stands, with the floor jack, remove the jack stands from under the van and slowly lower it to the ground.

Tighten the lug nuts to 85 to 115 foot-pounds, using the torque wrench and a socket.

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