The Mercury Villager was the product of a joint venture between Ford Motor Company and Nissan Motors. It was a domesticated version of the Nissan Quest manufactured in Ohio from 1993 to 2002. The Villager, like most vehicles manufactured after the mid-1970s, uses front disc brakes. The front brakes account for up to 75 per cent of the braking power for the vehicle and therefore may require more service than rear brakes. Replacing the pads before they wear too thin will optimise your braking ability as well as potentially save other braking components from damage.
Remove about half of the brake fluid from the master cylinder with a brake fluid syringe. Replace the cover to the master cylinder.
Apply the parking brake and then place a wheel block behind one of the rear tires.
Loosen the lug nuts of the front tires with a lug wrench no more than half a turn. Perform this on both tires if you're lifting and supporting the entire front axle onto jack stands, or just do one side at a time if you're only using one jack stand.
Raise and support the Villager with a jack and jack stands. Do not use the jack alone as a support for the vehicle.
Use the ratchet and Torx T-40 bit to remove the upper and lower caliper bolts.
Use a screwdriver or pry tool to remove the caliper from the anchor plate and rotor by prying it out from the bottom. Support the caliper and pad assembly to the strut spring with a length of heavy-duty wire.
Use one screwdriver or pry tool to release the outboard brake pad retaining clip, then use the other screwdriver or pry tool to pry the pad from the caliper housing.
Compress the caliper piston inward fully, using a caliper piston retracting tool placed between the inside housing of the outboard caliper housing and the face of the inboard brake pad.
Pull the inboard pad and retainer from the caliper piston.
Replace the pads by reversing the procedure. Be sure to install the inboard pad first.
Remove the caliper from the wire and place it over the rotor and anchor plate. Align the caliper bolts and tighten them to 25ft-lbs. with the torque wrench and Torx T-40 bit.
Repeat the pad replacement for both front wheels and snug the lug nuts to the wheel rim with the lug wrench. Lower the Villager and then torque the nuts to 90ft-lbs. with a torque wrench and socket, using a star pattern.
Pump the brake pedal several times until firm to extend the caliper pistons. Release the parking brake and remove the wheel chock.
Check the level of brake fluid in the master cylinder and top it off with new brake fluid if necessary. Replace the cover and test-drive the Villager for braking performance.
Things you need
- Brake fluid syringe
- Wheel block
- Lug wrench
- Jack stand(s)
- 1/2-inch drive ratchet
- 1/2-inch drive Torx T-40 bit
- Heavy-duty wire
- 2 screwdrivers or small pry tools
- Caliper piston retracting tool
- Replacement brake pad set
- Torque wrench and socket
- Brake fluid