Complete disassembly, cleaning, inspection, and rebuild of front brake calipers using new seals and hardware, including bleeding and testing.

Warnings

Tools required

Parts

• Front brake caliper rebuild kit (seals, dust boots, o-rings) × 2 — Use OEM or quality aftermarket kit for 2011-2014 F-150
• Brake caliper slide pin boot kit × 2 — Verify compatibility with single-piston caliper
• Silicone brake grease (high-temperature caliper lube) × 1 — Use brake-specific silicone grease
• Threadlocker (medium strength) × 1 — Blue Loctite 242 or equivalent

Fluids

• Motorcraft DOT 4 LV Brake Fluid — 1 qt

Preparation

1. Park vehicle on level surface, engage parking brake, and chock rear wheels
2. Remove approximately half the brake fluid from master cylinder reservoir using turkey baster or fluid transfer pump to prevent overflow during piston compression
3. Loosen front wheel lug nuts while vehicle is on ground
4. Raise front of vehicle and secure on jack stands rated for vehicle weight (minimum 3-ton capacity)
5. Remove both front wheels completely
6. Clean caliper exterior, mounting bracket, and surrounding area with brake cleaner to prevent contamination during disassembly
7. Open hood and keep accessible for master cylinder monitoring during bleeding process

Procedure

1. 1

   Remove caliper from bracket
   Remove lower and upper caliper slide pin bolts using appropriate socket. Support caliper weight and lift off bracket. Immediately support caliper using safety wire or bungee cord attached to suspension component - do NOT allow it to hang by brake hose.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
2. 2

   Disconnect brake hose
   Place drain pan beneath caliper. Using appropriate wrench, disconnect brake hose banjo bolt from rear of caliper. Immediately plug or cap the brake hose end to prevent fluid loss and contamination. Remove caliper to workbench. Expect significant brake fluid drainage.
   ⚠Brake fluid will drain freely. Have adequate catch container positioned.
3. 3

   Extract caliper piston
   Position caliper with piston facing up on clean work surface. If available, use controlled compressed air (maximum 30 PSI) directed into brake hose port to push piston out. Apply air in short bursts while controlling piston with gloved hand. Alternatively, use soft-jaw pliers to carefully extract piston by hand. Do NOT damage piston chrome surface.
   ⚠Piston can eject forcefully if using compressed air. Keep hands clear and use only low pressure.
4. 4

   Remove seals and boots
   Use pick tool to carefully remove piston dust boot from caliper body groove. Extract square-cut piston seal from internal bore groove using pick - work carefully to avoid scratching bore surface. Remove bleeder screw dust cap and inspect bleeder screw threads. If slide pins are in poor condition, remove slide pin boots from bracket.
   Torque spec

   Bleeder Screw10 Nm (7 lb-ft)
5. 5

   Inspect caliper components
   Thoroughly inspect caliper bore for scoring, pitting, rust, or corrosion. Any visible damage to the bore surface requires caliper replacement - do NOT attempt to rebuild damaged calipers. Inspect piston chrome surface for pitting, scoring, or corrosion; replace piston if any damage exists. Check bleeder screw threads for damage. Verify caliper bracket slide pin bores are not excessively worn.
   ⚠️Do not rebuild calipers with damaged bores or pistons. This can cause seal failure and complete brake loss.
6. 6

   Clean all components
   Clean caliper bore, piston, and all internal passages thoroughly with brake cleaner and lint-free rags. Use wire brush to clean external caliper surfaces and mounting surfaces. Flush all fluid passages with fresh brake cleaner. Dry completely with compressed air or allow to air dry. Clean caliper bracket mounting surfaces and slide pin bores.
   ⚠Ensure all components are completely clean and dry before assembly. Any contamination can cause seal failure.
7. 7

   Install new piston seal
   Verify rebuild kit components match original parts. Coat new square-cut piston seal lightly with clean DOT 4 LV brake fluid. Carefully install seal into caliper bore groove using only fingers - ensure seal seats completely in groove without twisting or rolling. Verify seal is properly positioned around entire circumference.
   ⚠Do not use tools to install seal. Use only clean brake fluid for lubrication, never petroleum products.
8. 8

   Install piston and dust boot
   Coat piston surface and new dust boot liberally with clean DOT 4 LV brake fluid. Position dust boot in caliper body outer groove first. Insert piston into bore straight and square, applying steady even pressure. Push piston fully into bore, compressing seal. Ensure dust boot seats properly in both caliper groove and piston groove. Verify piston moves smoothly in bore without binding.
   ⚠Piston must enter bore perfectly straight to avoid seal damage. Do not cross-thread or cock piston.
9. 9

   Service slide pins and hardware
   Remove caliper slide pins from bracket. Clean slide pins thoroughly with brake cleaner, removing all old grease. Inspect pins for scoring or corrosion; replace if damaged. Install new slide pin boots onto bracket if included in kit. Apply thin coating of silicone brake grease to slide pin shafts (not threads). Reinstall slide pins into bracket, ensuring boots seat properly.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
10. 10

    Reinstall caliper to vehicle
    Position rebuilt caliper onto mounting bracket, aligning slide pin bolt holes. Apply medium-strength threadlocker to slide pin bolt threads. Install and hand-tighten both slide pin bolts. Torque slide pin bolts to specification in a criss-cross pattern. Reconnect brake hose to caliper using new copper crush washers. Torque banjo bolt to appropriate specification.
    Torque spec

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)
11. 11

    Repeat for opposite side
    Complete the entire rebuild procedure (steps 1-10) for the second front caliper. Both front calipers should be rebuilt during same service interval to ensure balanced braking performance.
    ℹ️Rebuilding only one caliper can result in uneven braking and vehicle pull.
12. 12

    Bleed brake system
    Fill master cylinder reservoir to MAX line with fresh Motorcraft DOT 4 LV brake fluid. Starting with right front caliper, attach bleeder hose to bleeder screw with other end submerged in clean brake fluid container. Loosen bleeder screw one full turn. Have assistant slowly depress brake pedal fully and hold. Tighten bleeder screw, then release pedal. Repeat until fluid flows clear without air bubbles. Torque bleeder screw to specification. Repeat process for left front. Check master cylinder level frequently and maintain at MAX.
    ⚠️Never allow master cylinder to run dry during bleeding. This introduces air into ABS system requiring professional scan tool bleeding.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
13. 13

    Perform pedal feel test
    With engine off, pump brake pedal 15-20 times to verify firm pedal. Pedal should become progressively firmer and maintain solid feel. If pedal feels spongy or sinks slowly, repeat bleeding procedure. Start engine and verify power-assisted braking functions normally with no pedal fade.
    ⚠️Do not operate vehicle if brake pedal feels soft, spongy, or sinks to floor. This indicates air in system or component failure.
14. 14

    Reinstall wheels and perform final checks
    Reinstall both front wheels. Hand-tighten all lug nuts in star pattern. Lower vehicle to ground. Torque wheel lug nuts to specification in star pattern using torque wrench. Double-check all caliper mounting bolts are properly torqued. Inspect area beneath vehicle for any brake fluid leaks.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Verify master cylinder reservoir is at MAX level with fresh DOT 4 LV brake fluid
2. Confirm no brake fluid leaks at caliper hose connections or bleeder screws
3. Ensure all caliper slide pin bolts and hardware are properly torqued to specification
4. Verify wheels are torqued in proper star pattern to specification

Verification

• Pump brake pedal with engine off - should achieve firm pedal within 3-4 pumps
• Start engine and verify power brake assist functions normally
• Perform test drive in safe area at low speed (under 15 mph) to verify even braking with no pull to either side
• Check for any vibration, noise, or pulsation during light brake application
• Perform several moderate stops from 25-30 mph to seat pads and verify proper brake response
• After test drive, re-inspect all connections for leaks and verify master cylinder fluid level
• CRITICAL: If any abnormal brake behavior occurs, do NOT operate vehicle - seek professional diagnosis immediately

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