Replace a single front brake rotor on a 2015-2020 Ford F-150 3.5L EcoBoost, including caliper removal, rotor replacement, and proper torquing of all brake components.

Warnings

Tools required

Parts

• Front brake rotor (single) × 1 — OEM: BR3Z-1125-A or equivalent aftermarket
• Rotor set screws (if corroded) × 1 — M6 x 1.0 x 10mm

Fluids

• Motorcraft DOT 4 LV Brake Fluid

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen front wheel lug nuts 1/4 turn while vehicle is on the ground
3. Lift front of vehicle using floor jack at designated lift point and secure with jack stands under frame rails
4. Remove wheel completely and set aside
5. Check brake fluid level in master cylinder reservoir and remove cap to allow fluid displacement when compressing caliper piston
6. Inspect brake system for leaks, damaged hoses, or excessive wear before proceeding

Procedure

1. 1

   Remove caliper slide pin bolts
   Using an 18mm socket, remove the two caliper slide pin bolts (also called guide pin bolts) that secure the brake caliper to the caliper bracket. These are located on the back side of the caliper assembly. 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 brake caliper off the rotor and caliper bracket. Do NOT let it hang by the brake hose. Use wire or a bungee cord to hang the caliper from the suspension or frame in a way that does not stress or kink the brake hose. Ensure the caliper is secure and will not fall.
3. 3

   Remove caliper bracket bolts
   Using a 21mm socket, remove the two caliper bracket bolts that secure the bracket to the steering knuckle. These bolts are typically very tight and may require a breaker bar. Once removed, take off the entire caliper bracket assembly. Note the position of any anti-rattle clips or shims for reassembly.
   ⚠These bolts are torqued to high specification. Use proper socket depth to avoid rounding bolt heads.
   Torque spec

   Caliper Bracket Bolts117 Nm (86 lb-ft)
4. 4

   Remove rotor set screws
   Using a T30 Torx or Phillips screwdriver, remove the rotor set screw(s) that secure the rotor to the hub. These screws are often corroded and may require penetrating oil. If stripped or seized, they can be drilled out as they are not structurally critical (wheel studs hold rotor in place during operation).
   ℹ️Set screws are only for assembly retention and can be replaced or omitted if damaged beyond removal.
   Torque spec

   Rotor Set Screws8 Nm (6 lb-ft)
5. 5

   Remove old brake rotor
   Pull the brake rotor straight off the wheel hub. If rotor is stuck due to corrosion, tap gently around the rotor face (not friction surface) with a rubber mallet or use a threaded puller in the tapped holes if equipped. Do not damage the wheel studs or hub surface.
6. 6

   Clean hub surface
   Using a wire brush, thoroughly clean the hub mounting surface where the rotor sits. Remove all rust, corrosion, and debris. The surface must be clean and flat to ensure the new rotor seats properly and runs true without wobble. Clean the wheel studs with a wire brush as well.
   ⚠Any debris or corrosion left on hub face will cause rotor runout and brake pulsation.
7. 7

   Install new brake rotor
   Apply a thin coat of anti-seize compound to the cleaned hub surface (avoid getting on wheel studs). Remove any protective coating from the new rotor using brake parts cleaner on both friction surfaces. Place the new rotor onto the hub, aligning the set screw hole(s). Install the rotor set screw(s) and tighten to specification.
   ℹ️New rotors have a protective oil coating that MUST be removed with brake cleaner to prevent reduced braking performance and noise.
   Torque spec

   Rotor Set Screws8 Nm (6 lb-ft)
8. 8

   Reinstall caliper bracket
   Clean the caliper bracket bolt holes in the steering knuckle with a wire brush. Apply medium-strength thread-locking compound to the caliper bracket bolt threads as recommended. Position the caliper bracket over the rotor and align with mounting holes. Install both bracket bolts and torque to specification in an alternating pattern.
   ⚠Caliper bracket bolts are critical fasteners. Ensure threads are clean and torque is accurate.
   Torque spec

   Caliper Bracket Bolts117 Nm (86 lb-ft)
9. 9

   Compress caliper piston
   Before reinstalling the caliper, the piston must be compressed to accommodate the thicker new rotor. Use a brake caliper piston compression tool or large C-clamp to slowly compress the piston back into the caliper bore. Monitor the brake fluid reservoir to ensure it does not overflow; remove fluid with a turkey baster if necessary.
   ⚠Compress piston slowly to avoid damaging caliper seals. Do not use excessive force.
10. 10

    Reinstall brake caliper
    Apply a thin coat of silicone brake grease to the caliper slide pin bolt shafts (not the threads). Position the caliper over the rotor and align with the bracket. Insert both slide pin bolts and torque to specification in an alternating pattern. Ensure caliper moves freely on the slide pins.
    ℹ️Proper lubrication of slide pins is essential for even brake pad wear and caliper function.
    Torque spec

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

    Reinstall wheel and lower vehicle
    Install the wheel onto the hub, ensuring it seats flush. Install all lug nuts by hand. Tighten lug nuts in a star pattern to snug. Lower the vehicle until the tire just touches the ground. Torque lug nuts to specification in a star pattern. Fully lower vehicle and remove jack stands.
    ⚠Always use star pattern when torquing lug nuts to ensure even clamping force and prevent rotor warping.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)
12. 12

    Restore brake pedal pressure
    Before moving the vehicle, pump the brake pedal several times until it becomes firm. This reseats the caliper piston against the new rotor. Check the brake fluid level in the master cylinder reservoir and top off with Motorcraft DOT 4 LV brake fluid if necessary. Reinstall reservoir cap.
    ⚠️Vehicle will have NO brakes until pedal is pumped to restore pressure. Do not attempt to move vehicle until pedal is firm.

Reassembly

1. Ensure all fasteners have been torqued to specification using a calibrated torque wrench
2. Verify brake caliper is not contacting suspension components and moves freely
3. Check that brake hose is not twisted, kinked, or under tension
4. Confirm brake fluid reservoir is at proper level between MIN and MAX marks
5. Inspect work area for any tools or parts left behind

Verification

• Pump brake pedal 5-10 times and verify firm pedal feel with no excessive travel
• Check for any brake fluid leaks around caliper connections and bleeder screw
• Start engine and verify brake warning light is off (applies brake boost)
• Test brakes at low speed (5-10 mph) in a safe area to confirm proper function before driving
• Listen for any unusual noises during initial brake applications (light squeaking during break-in is normal)
• Perform bed-in procedure: Make 10-15 moderate stops from 30-40 mph to properly seat pads to new rotor surface
• Recheck lug nut torque after driving 50-100 miles
• Be aware that new rotors require 200-300 miles of break-in for optimal performance

More procedures for this vehicle