Replace front brake rotors on a 2015-2020 Ford F-150 3.5L EcoBoost, including caliper removal, rotor replacement, and proper torque specifications for safe brake operation.

Warnings

Tools required

Parts

• Front brake rotors × 2 — Use OEM specification or quality aftermarket
• Rotor set screws (if corroded) × 2 — M8 x 1.25mm

Fluids

• Motorcraft DOT 4 LV Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on level, solid ground and set parking brake firmly
2. Chock rear wheels securely to prevent vehicle movement
3. Loosen front wheel lug nuts 1/4 turn while vehicle is on ground (do not remove)
4. Lift front of vehicle with floor jack at designated front jacking point
5. Place jack stands under frame rails at appropriate support points
6. Lower vehicle onto jack stands and verify stability before proceeding
7. Remove front wheels completely and set aside
8. Verify you have correct replacement rotors for your specific F-150 model (rotor diameter and thickness vary by trim level)

Procedure

1. 1

   Inspect brake system and clean work area
   Visually inspect the brake caliper, brake lines, and rotor for damage or excessive wear. Check brake pad thickness - if below 3mm, plan to replace pads as well. Spray brake assembly with brake cleaner and wipe away brake dust with a cloth. Never use compressed air to clean brake components.
2. 2

   Remove caliper slide pin bolts
   Locate the two caliper slide pin bolts on the back of the caliper. Using an 18mm socket or wrench, remove both slide pin bolts completely. The caliper will now be free to pivot away from the rotor. If bolts are seized, apply penetrating oil and allow to soak before removal.
   ⚠Keep track of slide pin bolts and inspect threads for damage. These bolts are torque-critical for safe brake operation.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
3. 3

   Secure caliper away from work area
   Carefully lift the caliper assembly off the rotor. Do NOT let it hang by the brake hose. Use wire, a bungee cord, or hook to support the caliper from the suspension or frame. Ensure there is no tension or stress on the rubber brake line. Inspect the brake hose for cracks, leaks, or damage while accessible.
4. 4

   Remove caliper bracket bolts
   Locate the two large caliper bracket bolts securing the bracket to the steering knuckle (these are larger than the slide pin bolts). Using an 18mm or 21mm socket (verify size for your specific bracket), remove both caliper bracket bolts completely. The bracket will now be free to remove along with the brake pads.
   ℹ️These bolts require threadlocker on reinstallation and are torqued to 120 Nm (88 lb-ft).
   Torque spec

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

   Remove caliper bracket and brake pads
   Pull the caliper bracket assembly away from the rotor. The brake pads will either stay with the bracket or fall free. Inspect brake pads for uneven wear, glazing, or contamination. Measure pad thickness - if less than 3mm of friction material remains, replace pads during this service. Set bracket and pads aside in clean location.
6. 6

   Remove rotor set screws and old rotor
   Locate the small set screw(s) in the face of the rotor hub (typically one or two Phillips or T-25 Torx screws). Remove set screw(s) completely. If corroded or stripped, they can be drilled out and replaced. Pull the rotor straight off the hub. If rotor is stuck due to corrosion, tap from behind with a rubber mallet or use rotor puller - never strike the rotor face directly.
   ⚠Rotors can be heavy and may fall suddenly when freed. Support rotor while removing to prevent injury.
   Torque spec

   Rotor Set Screws8 Nm (6 lb-ft)
7. 7

   Clean hub mounting surface
   Use a wire brush to thoroughly clean the hub face where the rotor mounts, removing all rust, corrosion, and debris. This ensures the new rotor sits flush and prevents runout issues that cause vibration and uneven wear. Spray with brake cleaner and wipe clean. The hub surface should be smooth and metallic.
8. 8

   Install new rotor
   Remove protective coating from new rotor using brake cleaner (rotors are shipped with oil coating to prevent rust). Clean both sides thoroughly and wipe dry. Slide new rotor onto hub, ensuring it sits completely flush against the hub face. Install rotor set screw(s) and torque to specification using torque wrench.
   ℹ️Do not overtighten set screws - they are only meant to hold rotor during assembly. Torque to 8 Nm (6 lb-ft) maximum.
   Torque spec

   Rotor Set Screws8 Nm (6 lb-ft)
9. 9

   Compress brake caliper piston
   Before reinstalling caliper bracket, the caliper piston must be compressed to accommodate the new (thicker) rotor and pads. Remove master cylinder reservoir cap to prevent pressure buildup. Using a C-clamp or brake piston tool, slowly compress the piston fully into the caliper bore. Monitor brake fluid level in reservoir - it will rise as piston is compressed. Remove excess fluid with turkey baster if needed to prevent overflow.
   ⚠Compress piston slowly to avoid damaging caliper seals. Never force piston at an angle.
10. 10

    Reinstall caliper bracket
    Position caliper bracket over new rotor and align bolt holes with steering knuckle. Apply blue threadlocker to caliper bracket bolt threads as specified. Install both bracket bolts hand-tight, then torque to specification in a cross pattern using torque wrench. Verify bracket is secure and does not move.
    ⚠️Caliper bracket bolts are critical fasteners. Must be torqued to exactly 120 Nm (88 lb-ft) with threadlocker applied.
    Torque spec

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

    Reinstall brake pads
    If reusing existing pads, ensure they are clean and in good condition. Install brake pads into caliper bracket with friction material facing the rotor. Pads should slide smoothly in bracket channels. Apply a thin layer of silicone brake grease to pad backing plate edges where they contact bracket (do not get grease on friction material or rotor surface).
12. 12

    Reinstall caliper and slide pin bolts
    Remove caliper from support wire/bungee. Position caliper over brake pads and align slide pin bolt holes with bracket. Apply silicone brake grease to slide pin bolt threads and smooth portions as specified. Install both slide pin bolts hand-tight, then torque to specification using torque wrench. Ensure caliper moves freely on slide pins without binding.
    ⚠️Slide pin bolts must be torqued to exactly 35 Nm (26 lb-ft) with brake grease applied. Incorrect torque or dry bolts can cause uneven braking or caliper seizure.
    Torque spec

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)
13. 13

    Repeat for opposite side
    Repeat steps 1-12 for the opposite front brake rotor. Both front rotors should be replaced as a pair to ensure even braking performance. Use same torque specifications and procedures for both sides.
14. 14

    Reinstall wheels and lower vehicle
    Install front wheels, threading lug nuts by hand to prevent cross-threading. Tighten lug nuts in star pattern until snug but not fully torqued. Raise vehicle slightly with jack to remove jack stands. Lower vehicle completely to ground. Torque wheel lug nuts to specification in star pattern using torque wrench.
    ⚠️Wheel lug nuts must be torqued to 140 Nm (103 lb-ft) in star pattern. Incorrect torque can cause wheel loss while driving.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Reinstall master cylinder reservoir cap securely
2. Check brake fluid level and top off with Motorcraft DOT 4 LV brake fluid if needed to MAX line
3. Do not mix brake fluid types - only use DOT 4 LV specification
4. Pump brake pedal slowly 15-20 times with vehicle off to seat brake pads against new rotors
5. Check brake pedal firmness - pedal should become firm within 3-4 pumps and hold pressure

Verification

• With engine off, pump brake pedal firmly 10 times. Pedal should feel firm and not sink to floor
• Start engine and apply brakes - pedal should remain firm with no excessive travel or sinking
• Check for brake fluid leaks around caliper connections, bleeder screws, and brake lines
• Test drive in safe area at low speed (under 15 mph) and apply brakes gently - vehicle should stop smoothly without pulling to either side
• Perform 5-10 gentle brake applications from 30 mph to properly bed in new rotors (avoid hard braking for first 100 miles)
• After test drive, recheck wheel lug nut torque and inspect for any fluid leaks
• Listen for unusual brake noises (grinding, squealing beyond initial break-in) and check for vibration during braking
• If brake pedal feels soft, pumps up, or sinks, or if vehicle pulls during braking, DO NOT DRIVE - have vehicle towed to qualified technician

More procedures for this vehicle