Brake Caliper Rebuild - Rear

This procedure covers disassembly, cleaning, inspection, and rebuild of the rear brake calipers on a 2011-2014 Ford F-150 5.0L V8 4WD, including piston seal replacement and proper bleeding.

Warnings

Tools required

Parts

• Rear brake caliper rebuild kit (includes piston seals, dust boots, and hardware) × 2 — Use OEM Ford specification or quality aftermarket
• Brake fluid reservoir cap gasket × 1 — Replace if damaged

Fluids

• Motorcraft DOT 4 LV Brake Fluid — 1 qt

Preparation

1. Park vehicle on level concrete surface and engage parking brake firmly
2. Loosen rear wheel lug nuts 1/4 turn while vehicle is on ground
3. Lift rear of vehicle and support on jack stands positioned on frame rails - never work under a vehicle supported only by a jack
4. Remove rear wheels completely
5. Locate brake fluid reservoir under hood and check fluid level - note current level for reference
6. Place cardboard or plastic sheeting under work area to catch brake fluid drips
7. Inspect brake lines and hoses for damage, corrosion, or leaks before proceeding

Procedure

1. 1

   Remove caliper from vehicle
   Open bleeder screw 1/4 turn and attach a clear hose leading to catch container. Have assistant gently press brake pedal to push piston back into bore and drain some fluid, then close bleeder before pedal returns. Remove caliper slide pin bolts using appropriate socket. Lift caliper off rotor and bracket. Support caliper - do not let it hang by brake hose. Disconnect brake hose from caliper by removing banjo bolt. Immediately plug hose end with clean rubber cap to prevent fluid loss and contamination. Cap caliper inlet port as well.
   Torque spec

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

   Remove piston from caliper bore
   Take caliper to clean workbench. Remove dust boot retaining ring if present. For rear calipers with integrated parking brake, the piston must be rotated counter-clockwise while pulling outward using the wind-back tool - do NOT use compressed air on parking brake calipers as this can damage the internal mechanism. If using compressed air method on non-parking brake calipers, hold caliper with bore facing away from you and cover opening with shop towel. Apply low pressure air (15-20 PSI maximum) to brake hose inlet while controlling piston movement. Once piston is removed, inspect parking brake actuator spindle inside piston bore.
   ⚠️Piston can eject with significant force. Always direct away from body and face. Use minimal air pressure and maintain control.
3. 3

   Remove old seals and inspect bore
   Using plastic pick tool (never metal), carefully remove square-cut piston seal from groove in caliper bore. Remove any remaining dust boot material. Clean caliper bore thoroughly with brake parts cleaner and lint-free towels. Inspect bore for scoring, pitting, corrosion, or scratches. Any defects deeper than 0.001 inch require caliper replacement - rebuilding a damaged bore will result in immediate seal failure. Check that bleeder screw moves freely; if seized, soak with penetrating oil or replace.
4. 4

   Clean and inspect piston
   Clean piston exterior thoroughly with brake parts cleaner. Inspect piston surface for scoring, corrosion, pitting, or chrome plating damage. Check piston diameter with micrometer at multiple points - variation more than 0.002 inch or any surface defects require piston replacement (purchase complete caliper). Inspect dust boot groove on piston for damage. For parking brake calipers, check that piston threads are clean and undamaged. Clean all caliper slide pin bores and hardware mounting points.
5. 5

   Install new piston seal
   Apply thin coat of fresh DOT 4 LV brake fluid to caliper bore. Remove new piston seal from rebuild kit - inspect for damage or contamination. Lubricate seal with brake fluid. Using clean fingers (gloved), carefully install seal into groove in caliper bore, ensuring seal is seated properly all around circumference without twisting or rolling. Do not use any petroleum-based lubricants which will cause seal failure.
6. 6

   Install dust boot and piston
   Install new dust boot into caliper body groove per rebuild kit instructions - some boots install before piston, others after. Lubricate piston exterior and bore with fresh brake fluid. For parking brake calipers, ensure piston slots or flats are properly aligned with actuator spindle before insertion. Carefully push piston into bore by hand, ensuring it enters squarely without cocking. For parking brake type, you may need to rotate piston clockwise while pressing. Push piston fully into bore. Seat dust boot into piston groove, ensuring no folds or damage.
7. 7

   Clean and lubricate slide pins
   Remove slide pins from caliper bracket if not already removed. Clean pins thoroughly with brake cleaner and inspect for corrosion, bending, or wear. Clean slide pin bores in bracket. Apply silicone brake grease (from rebuild kit or high-temp synthetic brake grease) to slide pins per manufacturer instructions - typically thin coat on pin shaft, avoiding threaded area. Install new slide pin boots from rebuild kit if included. Ensure pins move freely in bores.
8. 8

   Reinstall caliper to vehicle
   Remove caps from brake hose and caliper inlet. Install new copper crush washers (from rebuild kit) on both sides of banjo fitting. Connect brake hose to caliper and install banjo bolt finger-tight, then torque to specification. Position caliper over rotor and bracket, ensuring brake pads are properly positioned (if reusing old pads). Apply silicone brake grease to slide pin bolt threads and contact areas per torque spec notes. Install and torque slide pin bolts to specification.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
9. 9

   Bleed brake caliper
   Fill brake fluid reservoir to MAX line with fresh Motorcraft DOT 4 LV brake fluid. Attach clear hose to bleeder screw with other end submerged in clean brake fluid in catch container. Open bleeder screw 1/2 turn. If using vacuum bleeder, apply vacuum until fluid flows bubble-free. If manual bleeding, have assistant slowly press brake pedal to floor, hold, then close bleeder before pedal returns. Repeat 5-10 times until fluid flows clear with no air bubbles. Torque bleeder screw to specification - do not overtighten as threads will strip easily. Check reservoir level frequently and maintain above MIN line during bleeding.
   ⚠Never allow brake fluid reservoir to run dry during bleeding or air will enter ABS hydraulic unit, requiring professional scan tool bleeding procedure.
   Torque spec

   Bleeder Screw10 Nm (7 lb-ft)
10. 10

    Repeat process for opposite side
    Repeat all disassembly, cleaning, inspection, rebuild, installation, and bleeding steps for the opposite rear caliper. Both rear calipers should be rebuilt simultaneously to ensure balanced braking performance. Bleed the second caliper using the same procedure as step 9.
11. 11

    Final brake system bleeding
    After both rear calipers are installed and individually bled, perform complete brake system bleed in proper sequence: right rear, left rear, right front, left front. This ensures any air introduced during caliper removal is purged from system. Top off brake fluid reservoir to MAX line when complete. Pump brake pedal 15-20 times to seat pads and build pressure. Pedal should feel firm with no excessive travel.
12. 12

    Install wheels and perform final torque
    Install rear wheels and hand-tighten lug nuts in star pattern. Lower vehicle until wheels just contact ground but suspension is not loaded. Torque lug nuts to specification in star pattern using torque wrench. Fully lower vehicle and remove jack stands. Perform final lug nut torque verification in star pattern.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Ensure all bleeder screws are closed and torqued properly
2. Verify brake fluid reservoir is filled to MAX line with fresh DOT 4 LV fluid
3. Check all brake line connections for leaks - look for fluid seepage at banjo bolts
4. Ensure no tools or parts are left in wheel well or under vehicle
5. Verify parking brake operates correctly and releases fully

Verification

• With vehicle still on jack stands and engine off, pump brake pedal firmly 20 times - pedal should become firm and hold steady pressure without sinking
• Start engine and verify power brake assist is functioning - pedal should drop slightly when engine starts
• Inspect all brake connections for leaks while assistant holds firm pedal pressure for 30 seconds
• Test drive vehicle at low speed (under 15 mph) in safe private area, verifying brakes respond normally without pulling to either side
• Perform gradual brake applications at progressively higher speeds up to 30 mph, checking for proper brake feel, no pedal pulsation, and straight-line stopping
• Check brake fluid level after test drive - top off if needed and inspect calipers for any signs of leakage
• If pedal feels soft or spongy, repeat bleeding procedure starting with rear calipers
• Re-torque wheel lug nuts after 50-100 miles of driving

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