Not before 28 days of expiry. Apply for Settled status. Mostly likely you will not receive any physical card anymore only online status. If you are travelling from abroad they need physically proof them print out the status proof from HO website and keep it with you and tell them it is all online ...

I am an Albanian national with valid pre-settled status under the EUSS, valid until September 2025. I am married to an EU national and applied for settled status on February 25th, upon completing my 5 years of continuous residence. At that time, my Biometric Residence Card (BRC) had expired. Key ...