Brake Caliper - Rear

This procedure covers the removal and replacement of the rear brake caliper on a 2015-2020 Ford F-150 with 3.5L EcoBoost engine, including brake fluid bleeding and torque specifications.

Warnings

Tools required

Parts

• Rear brake caliper × 1 — Use OEM specification
• Copper crush washers for brake line × 2 — Use OEM specification
• Threadlocker (if removing bracket) × 1 — Medium strength

Fluids

• Motorcraft DOT 4 LV Brake Fluid — 0.5 qt

Preparation

1. Park vehicle on level ground and engage parking brake. Place wheel chocks at front wheels.
2. Remove approximately half the brake fluid from master cylinder reservoir using turkey baster or fluid extractor to prevent overflow when compressing caliper pistons.
3. Loosen rear wheel lug nuts 1/4 turn while vehicle is on ground.
4. Lift rear of vehicle with floor jack and support securely on jack stands at frame contact points.
5. Remove rear wheel completely.
6. Verify you have the correct replacement caliper for the side being serviced (driver or passenger).

Procedure

1. 1

   Clean and prepare work area
   Spray brake assembly with brake cleaner and wipe down caliper, bracket, and brake line connection points. Use wire brush to clean caliper bolt threads and mounting surfaces. This prevents contamination during disassembly.
2. 2

   Remove caliper brake line
   Place drain pan under caliper. Using a flare nut wrench, carefully loosen and remove the brake line banjo bolt from the rear of the caliper. Immediately plug the brake line opening with a rubber cap or clean shop rag to minimize fluid loss and prevent contamination. Note the position of the copper crush washers on both sides of the banjo fitting - these must be replaced.
   ⚠Brake fluid will drain from the line. Have rags and drain pan positioned to catch fluid.
   Torque spec

   Brake Line Banjo Bolt25 Nm (18 lb-ft)
3. 3

   Remove caliper mounting bolts
   Locate the two caliper mounting bolts on the rear of the caliper assembly (accessible from behind). These are the bolts that allow the caliper to slide. Using a 1/2 inch ratchet and appropriate socket, remove both caliper mounting bolts completely. Support the caliper with your hand as you remove the second bolt.
4. 4

   Remove old caliper
   Carefully lift the caliper straight up and away from the brake rotor and caliper bracket. The caliper should slide off the bracket pins. Remove the caliper completely from the vehicle. Inspect the caliper bracket slide pins for damage, corrosion, or excessive wear - clean and lubricate with high-temperature brake grease if reusing.
5. 5

   Inspect brake components
   With caliper removed, inspect the brake rotor for excessive wear, scoring, or heat damage. Check rotor thickness with micrometer if available. Inspect brake pads on caliper bracket for remaining material (minimum 3mm). Inspect caliper bracket bolts and mounting surfaces for damage. If bracket removal is necessary, unbolt using appropriate socket and note threadlocker requirement on reassembly.
6. 6

   Prepare new caliper
   Remove new caliper from packaging. Verify it matches the old caliper exactly (mounting bolt positions, bleeder location, brake line connection). If the new caliper pistons are not fully retracted, use a C-clamp or caliper piston tool to compress them fully. Remove any shipping plugs or protective caps from the brake line port and bleeder screw.
   ℹ️Some replacement calipers come with brackets pre-installed. Verify configuration matches your application.
7. 7

   Install new caliper
   Position the new caliper over the brake rotor and align with the caliper bracket slide pins. Ensure the caliper slides fully onto the bracket pins and seats properly against the mounting surface. The brake pads should be positioned on both sides of the rotor.
8. 8

   Install caliper mounting bolts
   Thread both caliper mounting bolts by hand to prevent cross-threading. Once both bolts are hand-tight, use torque wrench to tighten to specification in a cross pattern (alternate between bolts). Verify caliper can slide freely on bracket pins after torquing.
9. 9

   Connect brake line
   Install NEW copper crush washers on both sides of the brake line banjo fitting (one washer against the caliper, one washer against the banjo bolt head). Position the banjo fitting onto the caliper brake line port, ensuring proper alignment. Thread the banjo bolt by hand, then torque to specification using torque wrench. Do not reuse old copper washers.
   ⚠Failure to use new copper washers will result in brake fluid leaks and system failure.
   Torque spec

   Brake Line Banjo Bolt25 Nm (18 lb-ft)
10. 10

    Bleed brake caliper
    Attach clear tubing to the bleeder screw and submerge the other end in a container with clean brake fluid. Have an assistant pump the brake pedal 3-4 times and hold pressure. Open the bleeder screw 1/4 turn using 8mm wrench while assistant maintains pedal pressure. Close bleeder before pedal reaches floor. Repeat until no air bubbles appear in tubing and fluid runs clear. Tighten bleeder screw to specification on final close.
    ⚠Never let the master cylinder reservoir run dry during bleeding or air will enter the system. Check and refill reservoir frequently.
    ℹ️If vehicle has ABS, additional bleeding procedures may be required. Consult service manual for ABS bleeding sequence.
    Torque spec

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

    Check brake fluid level
    Top off master cylinder reservoir to the MAX line with fresh Motorcraft DOT 4 LV brake fluid. Ensure reservoir cap is properly sealed. Wipe up any spilled fluid immediately.
12. 12

    Reinstall wheel
    Position wheel onto hub and thread all lug nuts by hand. Tighten lug nuts in a star pattern using hand tools until wheel is seated against hub. Lower vehicle until tire just contacts ground but vehicle weight is still on jack stands.
13. 13

    Final torque and lower vehicle
    Using torque wrench, tighten wheel lug nuts to specification in a star pattern. Fully lower vehicle to ground and remove jack stands. Torque lug nuts again in star pattern to verify proper torque with vehicle weight on suspension.

Reassembly

1. Ensure all brake line connections are tight and free of leaks.
2. Verify caliper mounting bolts are torqued to specification.
3. Confirm wheel lug nuts are properly torqued in star pattern.
4. Double-check brake fluid reservoir level is at MAX line.

Verification

• With vehicle still on jack stands or in neutral, pump brake pedal firmly 10-15 times. Pedal should become firm and hold pressure. If pedal sinks, re-bleed the system.
• Inspect all brake line connections for leaks while assistant applies firm brake pedal pressure.
• Check for fluid leaks at banjo bolt connection and bleeder screw.
• Start engine and apply brakes firmly. Recheck for leaks with engine running and brake booster assisting.
• Test drive vehicle at low speed (under 15 mph) in a safe area. Verify brakes engage properly and vehicle stops straight without pulling.
• After test drive, recheck all connections for leaks and verify brake fluid level has not dropped.
• Perform several moderate brake applications from 30-40 mph to seat pads properly before normal driving.

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