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How to Replace the Rotors on a Ford Excursion

by Jody L. Campbell

The Ford Excursion was manufactured between the years of 2000 and 2005 by the Ford Motor Company. The large SUV featured front disc brakes on both two-wheel drive and four-wheel drive models. Some Excursions in the two-wheel and four-wheel drive categories also featured rear disc brakes. The main component of disc brakes is the rotor, also referred to as the disc. The hydraulic pistons of the calipers extend outward on braking demand, squeezing the brake pad friction material against the surface of the rotor, thus slowing and stopping the vehicle.

Step 1

Park the Excursion on a level surface suitable for lifting and supporting the heavy SUV. Apply the parking brake only if you're replacing the front brake rotors. Turn off the air suspension button located in the rear of the vehicle.

Step 2

Place a wheel block or block of wood behind one of the rear tires for added safety when replacing the front brake rotors. Place the block in front of one of the front tires if you're replacing the rear brake rotors.

Step 3

Crack the lug nuts loose with a breaker bar and suitable socket on the wheels where you're replacing the rotors.

Step 4

Lift the Excursion with the weight-rated floor jack and support the axle onto weight-rated jack stands. Remove the lug nuts and wheels.

Step 5

Place a the C-clamp over the caliper so the top of the clamp is touching the inner caliper housing and the screwing bore of the clamp is against the bottom of the outer brake pad plate. Tighten the clamp just enough to allow room for the new rotor (a turn or two). Do not bottom the caliper pistons into their bores.

Step 6

Remove the upper and lower caliper plate bolts located on the back side of the knuckle with the breaker bar and a socket. Remove the caliper and plate assembly and then support it on the suspension with heavy-duty caliper wire.

Step 7

Remove the brake rotor from the hub. If the brake rotor does not come off the hub due to rust and other corrosives, spray the penetrating lubricant around the center hub hole of the rotor and allow a few minutes for the spray to soak in. Use a hammer to strike the inner plate of the rotor outward and turn the rotor 1/4 turn between strikes until the rotor breaks free from the hub. On rear rotors, strike the front hub of the rotor (being careful not to hit the lug studs) and turn 1/4 turn between strikes until the rotor breaks free from the hub.

Step 8

Spray the replacement rotor with brake/parts cleaner spray to remove the sticky rust preventative solution coating. Spray both sides thoroughly.

Step 9

Place the replacement rotor onto the hub and reverse the remaining procedure to reassemble the brakes and wheel.

Step 10

Tighten the caliper plate bolts to 148-foot pounds with the adjustable torque tool and a socket.

Step 11

Replace the wheels and lug nuts and snug the lugs nuts tightly to seat the wheels to the hub.

Step 12

Lower the Excursion and re-tighten the lug nuts with the adjustable torque tool set at 110 foot-pounds. Move from one lug nut to the opposite lug in a star or crisscross pattern.

Apply the brake pedal several times until it feels firm. Remove the wheel block, release the parking brake and turn the air suspension back on before test driving the Excursion.

Warning

  • Do not force the caliper assembly onto the new rotors. If you do not have enough room, simply remove the outer brake pad and reapply the C-clamp to the inner housing with a small piece of wood placed against the inboard pad and tighten the clamp a little more until the caliper assembly fits over the new rotors.

Items you will need

  • Wheel block or large block of wood
  • Breaker bar with socket set
  • Weight rated floor jack and jack stands, set of 2
  • 6-inch (or larger) C-clamp
  • Heavy-duty caliper wire
  • Penetrating lubricant spray
  • Ball peen hammer
  • Brake/parts cleaner spray
  • Replacement brake rotors
  • Adjustable foot-pound torque tool

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