This procedure replaces the electronic parking brake actuator on the rear caliper assembly, restoring proper parking brake function.

Warnings

Tools required

Parts

• Parking brake actuator × 1 — Motorcraft BRC-xxx or equivalent
• Brake fluid × 1 — Motorcraft DOT 4 LV
• Caliper mounting hardware kit (if corroded) × 1 — Use OEM specification

Fluids

• Motorcraft DOT 4 LV Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level, solid ground and place wheel chocks at front wheels
2. Ensure ignition is OFF and key is removed from vehicle
3. Connect scan tool and verify communication with parking brake control module
4. Using scan tool, enter parking brake service mode to retract actuator piston (this disables automatic parking brake and retracts the caliper piston)
5. Loosen rear wheel lug nuts 1/4 turn while vehicle is on ground
6. Raise rear of vehicle with floor jack and support securely on jack stands at frame rails
7. Remove rear wheel completely
8. Verify brake fluid level in master cylinder reservoir is not above MAX line (to prevent overflow during caliper work)

Procedure

1. 1

   Remove brake caliper from bracket
   Locate the two caliper slide pin bolts on the inboard side of the caliper. Remove both bolts completely. Carefully lift the caliper off the brake rotor. Do NOT let the caliper hang by the brake hose. Support it with a bungee cord or safety wire attached to the suspension or frame.
   Torque spec

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

   Disconnect parking brake actuator electrical connector
   Locate the electrical connector on the parking brake actuator motor (mounted on rear of caliper). Press the locking tab and disconnect the connector. Inspect connector terminals for corrosion and clean if necessary with electrical contact cleaner.
   ℹ️Take a photo of the connector orientation before removal for reference during reassembly.
3. 3

   Disconnect brake hose from caliper
   Place a drain pan beneath the caliper. Using a flare nut wrench, loosen and remove the brake hose banjo bolt from the caliper inlet port. Remove the two copper crush washers (one on each side of the banjo fitting). Plug the brake hose end with a clean rubber cap or tape to minimize fluid loss and contamination.
   ⚠Brake fluid will drain from the hose and caliper. Have rags and drain pan ready.
4. 4

   Remove parking brake actuator from caliper
   The actuator is typically secured by two or three T45 Torx bolts on the rear of the caliper assembly. Remove these bolts and carefully separate the actuator from the caliper body. Note the position of any O-rings or seals between the actuator and caliper.
   ⚠The actuator drive mechanism interfaces with the caliper piston screw. Separate carefully to avoid damaging internal components.
5. 5

   Prepare new actuator and caliper mating surface
   Clean the caliper mounting surface with brake parts cleaner and a wire brush. Remove any corrosion or old gasket material. Inspect the caliper piston screw mechanism for damage. If the new actuator includes O-rings or seals, install them on the actuator. If not included, transfer the old seals if they are in good condition (replace if damaged or deteriorated).
   ℹ️Some actuators come with pre-installed seals, others require reuse of existing seals. Verify parts kit contents before assembly.
6. 6

   Install new parking brake actuator
   Align the new actuator drive mechanism with the caliper piston screw. Carefully seat the actuator against the caliper body, ensuring proper engagement. Install the T45 Torx mounting bolts and tighten to specification per service manual (typically 10-15 Nm). Verify the actuator is flush against the caliper body with no gaps.
   ⚠Ensure the actuator drive gear properly meshes with the piston screw before tightening bolts, or actuator will fail.
7. 7

   Reconnect brake hose to caliper
   Install NEW copper crush washers on both sides of the banjo fitting (never reuse old washers). Thread the banjo bolt through the hose fitting and into the caliper inlet port. Tighten banjo bolt to 31 Nm (23 lb-ft). Ensure the brake hose is not twisted or kinked.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
8. 8

   Reconnect actuator electrical connector
   Reconnect the electrical connector to the parking brake actuator motor. Ensure the locking tab clicks into place securely. Gently tug on the connector to verify it is seated properly.
9. 9

   Apply brake grease and reinstall caliper
   Apply a thin layer of silicone brake grease to the caliper slide pins. Position the caliper over the brake pads and rotor. Install both caliper slide pin bolts and tighten to specification in an alternating pattern.
   Torque spec

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

    Bleed brake caliper
    Locate the bleeder screw on the rear of the caliper. Attach a clear hose to the bleeder and submerge the other end in a container of clean brake fluid. Have an assistant pump the brake pedal several times and hold pressure. Open the bleeder screw slightly (1/4 turn) to release air and old fluid. Close bleeder before pedal reaches floor. Repeat until fluid runs clear with no air bubbles. Tighten bleeder screw to specification.
    ⚠Never allow the brake pedal to go to the floor completely, as this can damage the master cylinder.
    ⚠Do not reuse brake fluid caught in the container. Dispose of properly.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
11. 11

    Calibrate parking brake actuator
    Using the scan tool, exit parking brake service mode. Follow the scan tool prompts to perform parking brake actuator calibration. This procedure typically involves several automatic apply/release cycles. Do not interrupt this process. Verify calibration completes successfully with no error codes.
    ⚠️Calibration is REQUIRED for proper parking brake function. Skipping this step will result in parking brake failure.
12. 12

    Reinstall wheel and lower vehicle
    Install the rear wheel and hand-tighten all lug nuts. Lower the vehicle until the tire just touches the ground (still supported by jack). Tighten lug nuts in a star pattern to specification. Fully lower vehicle and remove jack stands.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Check brake fluid level in master cylinder reservoir and top off to MAX line with Motorcraft DOT 4 LV brake fluid only
2. Pump brake pedal firmly several times until pedal feels firm and consistent
3. Verify no brake fluid leaks at caliper, banjo bolt connection, or bleeder screw
4. Test parking brake operation by activating and releasing several times, verifying actuator motor operates and brake holds vehicle on slight incline

Verification

• With engine running, firmly apply brake pedal and verify pedal is firm and does not sink
• Check for any brake fluid leaks around all connections worked on during this procedure
• Test drive vehicle in safe area at low speed (under 10 mph) to verify normal brake operation before returning to service
• Apply parking brake on a slight incline and verify vehicle is held securely without rolling
• Using scan tool, verify no parking brake fault codes are present
• Verify parking brake warning light on instrument cluster operates correctly (illuminates when engaged, off when released)
• Re-check brake fluid level after test drive and top off if necessary

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