How to Remove the Front Brake Rotor in a 2002 Mercury Villager

Replacing the rotors on a 2002 Mercury Villager is necessary if the rotors become warped (out of round or excessive runout) or have physical scores, rust pits or grooves. Because the rotor is the surface the brake pads use to apply friction in order to slow the front-wheel-drive van down, any of the above symptoms can create a pulsation, annoying squeals or premature brake pad wear.

Instructions

1

Apply the parking brake lever on the Mercury Villager after parking the van on a paved, even surface.

2

Loosen the front lug nuts on the front tire(s) by turning them 1/4 turn counterclockwise with a wheel nut wrench.

3

Use a bottle or scissors jack to raise the front of the Villager (one side at a time if removing both rotors), then rest the van onto jack stands under the front frame rails to support it safely.

4

Remove the wheel nuts and tires.

5

Use a ratchet and T-40 Torx head bit to remove the upper and lower caliper bolts.

6

Pry the caliper and pad assembly off the rotor and integral knuckle. Use the caliper hanger to hang the assembly from the front coil spring.

7

Remove the rotor from the wheel hub. If the rotor is stuck, apply lubricant spray to the mating surface of the front center hole in the rotor to the hub and allow it to soak for a few minutes. Strike the front hub face of the rotor with a dead-blow rubber mallet until the rotor breaks free from the hub.