How do you remove the front brake rotor from 2000 ford expedition?

Answer

Its pretty simple. Make sure you get the proper new rotors with either 12mm or 14mm holes in the rotors as the Expedition changed to 14mm sometime during production.

Once the wheel is removed, you'll need to removed the caliper pins. A Torx-45 should fit for the pins. They are not tight so be careful not to destroy the fins on the bolt when removing it. Once the pins are removed, use a screw driver to force back the dual pistons so that the pads are free to move. Pull off the caliper and support it with a wire coat hanger twisted appropriately. The pads will then pull put from the sides of the rotor.

Now remove the 2 bolts that attach the caliper mounting bracket. These bolts are very tight. Attach a closed end wrench to the bolt and bang it with a hammer until it moves. Use a quality wrench to not round off the bolts.

From a hardware store acquire two 9/16 bolt/washer/nut sets of grade 8. Use this bolt/washer/nut assemble behind the rotor in the holes of the caliper mounting bracket. As you tighten the bolts they will apply pressure to the rotor. At the same time, apply heat with a MAPP gas torch to the rotor on the side where pressure is being applied. Heat the rotor and continue tightening the bolts until you hear a loud, possibly very loud, pop. At that point, back off the bolts, rotate the rotor 180 degrees, and repeat. This time there will be no pop, the rotor will just start to walk off the hub. Turn off the heat and continue rotating and tightening until the rotor is off.

I used this procedure to change the rotors on my 2001 Expedition with 4wd. By the way, banging on the rotor will not work on the front rotors. Banging only worked on the back rotors.