Brake Rotor - Rear Single

This procedure covers the replacement of a single rear brake rotor on a 2011-2014 Ford F-150 with 3.5L EcoBoost engine and 4WD, including caliper removal and reinstallation.

Warnings

Tools required

Parts

• Rear brake rotor × 1 — Use OEM specification for 2011-2014 F-150 4WD rear
• Rotor set screw (if corroded) × 1 — M8 Phillips head set screw

Preparation

1. Park vehicle on level, solid ground and place wheel chocks on the front wheels
2. Ensure parking brake is fully released
3. Loosen rear wheel lug nuts while vehicle is still on the ground (do not remove)
4. Raise rear of vehicle with floor jack at designated jacking point on frame rail
5. Secure vehicle on jack stands rated for vehicle weight, placed at proper frame support points
6. Remove rear wheel completely and set aside
7. Spray caliper slide pin bolts and bracket bolts with penetrating oil if corroded (allow to soak 10-15 minutes)

Procedure

1. 1

   Remove caliper slide pin bolts
   Using a 17mm socket, remove the two caliper slide pin bolts from the rear of the caliper assembly. These bolts secure the caliper to the bracket and allow the caliper to slide. Keep these bolts as they will be reused.
   Torque spec

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

   Remove and support brake caliper
   Carefully lift the caliper off the rotor and bracket. Do NOT let it hang by the brake hose. Use a wire hanger, bungee cord, or caliper hook to securely support the caliper from the suspension or frame. Ensure no tension is placed on the rubber brake hose.
   ⚠️Allowing the caliper to hang by the brake hose can damage the hose internally, leading to brake failure.
3. 3

   Inspect brake pads and clean slide pins
   With the caliper removed, inspect the brake pads for remaining thickness and uneven wear. If replacing the rotor, consider replacing pads as well. Wipe the caliper slide pins clean and inspect the rubber boots for tears. Apply fresh silicone brake grease to the slide pins before reassembly.
4. 4

   Remove caliper bracket bolts
   Using a 21mm socket, remove the two caliper bracket bolts that secure the bracket to the rear axle hub. These bolts are typically very tight. A breaker bar may be needed. Once removed, lift the caliper bracket off the rotor and set aside.
   ⚠Caliper bracket bolts are torqued to high specification and may require significant force to break loose.
   Torque spec

   Caliper Bracket Bolts117 Nm (86 lb-ft)
5. 5

   Remove rotor set screw
   Locate the Phillips head set screw on the face of the rotor (typically centered). Use a Phillips screwdriver to remove this screw. If corroded or stripped, you may need to drill it out or use a screw extractor. This screw is only for assembly alignment and is not critical to reinstall if damaged.
   ⚠Set screws are often corroded and may strip. Apply penetrating oil and use proper-sized Phillips screwdriver to avoid stripping.
   Torque spec

   Rotor Set Screws8 Nm (6 lb-ft)
6. 6

   Remove old brake rotor
   Pull the rotor straight off the hub. If the rotor is stuck due to rust or corrosion, tap the rear surface with a dead blow hammer or rubber mallet. Alternate taps around the rotor to break it free evenly. Do not strike the rotor friction surface or use excessive force that could damage wheel studs.
7. 7

   Clean hub mounting surface
   Use a wire brush to thoroughly clean the hub mounting surface where the rotor seats. Remove all rust, corrosion, and debris. This ensures the new rotor sits flat and true. Clean the wheel stud threads as well. Apply a thin layer of anti-seize compound to the hub surface (avoid getting on wheel studs).
   ⚠Rust or debris on the hub mounting surface can cause rotor runout, leading to brake pulsation and uneven wear.
8. 8

   Install new brake rotor
   Remove any protective coating from the new rotor using brake cleaner and clean rags (both friction surfaces and hat). Slide the new rotor onto the hub, aligning the holes for the set screw and wheel studs. The rotor should sit flat against the cleaned hub surface.
9. 9

   Install rotor set screw
   Thread in the rotor set screw by hand first to ensure proper alignment, then tighten to specification using a Phillips screwdriver or torque-limiting screwdriver. Do not overtighten as these screws strip easily. If the original screw was damaged, you may omit this step as the wheel lug nuts will secure the rotor.
   Torque spec

   Rotor Set Screws8 Nm (6 lb-ft)
10. 10

    Reinstall caliper bracket
    Position the caliper bracket over the rotor and align with the mounting holes on the axle hub. Thread in both bracket bolts by hand to ensure proper thread engagement. Using a 21mm socket and torque wrench, tighten both bolts to specification in alternating fashion to ensure even seating.
    Torque spec

    Caliper Bracket Bolts117 Nm (86 lb-ft)
11. 11

    Reinstall brake caliper
    Ensure the caliper slide pins are cleaned and lubricated with fresh silicone brake grease. Position the caliper over the rotor and bracket, ensuring the brake pads straddle the rotor properly. Align the slide pin bolt holes. Thread both caliper slide pin bolts by hand, then torque to specification using a 17mm socket and torque wrench.
    ⚠Ensure brake pads are properly seated in the caliper bracket before tightening slide pin bolts. Misalignment can cause brake drag or noise.
    Torque spec

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)
12. 12

    Reinstall wheel and lower vehicle
    Mount the wheel onto the hub, aligning the holes with the wheel studs. Thread all lug nuts by hand to prevent cross-threading. Snug the lug nuts in a star pattern with the lug wrench, but do not fully tighten yet. Lower the vehicle until the tire just contacts the ground (still supported mostly by jack stands). Using a torque wrench, tighten the lug nuts to specification in a star pattern. Fully lower the vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Double-check that all caliper bolts and wheel lug nuts are torqued to proper specification
2. Verify that no tools or parts were left in the wheel well or under the vehicle
3. Pump the brake pedal firmly several times until it feels firm before attempting to move the vehicle

Verification

• With the vehicle still in park, pump the brake pedal multiple times. The pedal should become firm and not sink to the floor
• Inspect around the caliper for any brake fluid leaks
• Perform a low-speed test drive in a safe area, testing brake function at low speeds (under 10 mph) before normal driving
• Listen for any unusual noises such as grinding, squealing, or rubbing during initial brake applications (light noise during initial bedding is normal)
• Check that the vehicle stops straight without pulling to one side
• After 50-100 miles, re-check wheel lug nut torque to ensure they remain properly tightened
• If you replaced only one rear rotor, monitor for brake pulling or pulsation. Mismatched rear rotors can cause uneven braking

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