Electronic Parking Brake Motor

This procedure replaces the electronic parking brake (EPB) motor on the rear brake caliper assembly. This is a safety-critical brake system component requiring proper diagnostic scan tool operation and brake system verification.

Warnings

Tools required

Parts

• Electronic parking brake motor × 1 — Ford BC3Z-2B623-B or equivalent
• Caliper mounting bolt anti-seize compound × 1 — Use high-temp brake assembly grease
• Brake cleaner solvent × 1 — Non-chlorinated brake parts cleaner

Fluids

• Motorcraft DOT 4 LV Brake Fluid — 0.25 qt

Preparation

1. Verify you have a scan tool with Ford EPB service functions before beginning. Test scan tool communication with EPB module.
2. Park vehicle on level, solid surface. Place wheel chocks at front wheels.
3. Release electronic parking brake using cab switch.
4. Disconnect negative battery cable and wait 2 minutes for system capacitor discharge.
5. Loosen wheel lug nuts 1/4 turn while vehicle is on ground.
6. Raise rear of vehicle with floor jack and secure on jack stands at frame rails. Ensure vehicle is stable.
7. Remove rear wheel on side requiring EPB motor replacement.
8. Inspect brake caliper, rotor, and pads for damage or excessive wear that may indicate need for additional service.

Procedure

1. 1

   Connect scan tool and enter EPB service mode
   Reconnect negative battery cable temporarily. Turn ignition to ON position (do not start engine). Connect scan tool to OBD-II port under dash. Navigate to EPB service functions and select 'Caliper Piston Retract' or 'Service Mode' for the affected wheel. This electrically retracts the caliper piston fully and relieves tension on EPB motor. Monitor scan tool for confirmation that service mode is active. Once complete, turn ignition OFF and disconnect negative battery cable again.
   ⚠️Failure to retract EPB piston with scan tool before motor removal will cause internal damage to caliper mechanism and may cause motor to suddenly release under spring tension.
2. 2

   Remove brake caliper from bracket
   Locate the two caliper slide pin bolts on rear side of caliper. Using appropriate socket, remove both caliper slide pin bolts. Carefully pivot caliper upward off rotor and brake pads. Support caliper with hanger or mechanics wire attached to suspension component - do NOT let caliper hang by brake hose. Leave brake hose connected.
   ⚠Never allow caliper to hang unsupported by brake hose. Hose damage can cause brake fluid leaks and brake failure.
   Torque spec

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

   Remove brake pads and hardware
   With caliper removed, slide brake pads out of caliper bracket. Note orientation and position of pad anti-rattle clips and shims for reassembly. Remove and inspect hardware for damage or corrosion. Set pads aside - they will be reinstalled unless worn beyond service limits.
   ℹ️Take photos of brake pad hardware orientation before removal to ensure correct reassembly.
4. 4

   Disconnect EPB motor electrical connector
   Locate EPB motor electrical connector on back of caliper. Press release tab and carefully disconnect wiring harness from motor. Inspect connector terminals for corrosion or damage. Clean with electrical contact cleaner if necessary.
   ⚠Connector terminals are fragile. Do not force or bend pins during disconnection.
5. 5

   Remove EPB motor mounting bolts
   Identify the EPB motor mounting bolts (typically two Torx head bolts) securing motor to rear of caliper housing. Using appropriate Torx bit, remove both mounting bolts. Note bolt length and position as they may differ.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
6. 6

   Remove EPB motor from caliper
   Carefully pull EPB motor straight back away from caliper housing. Motor shaft engages with internal caliper piston mechanism - it may require slight rotation and gentle pulling to disengage. Do NOT pry or use excessive force. Once disengaged, remove motor and inspect motor shaft and caliper mating surface for damage, debris, or corrosion.
   ⚠Motor shaft has precision gear teeth that must not be damaged. Handle motor carefully and do not drop.
7. 7

   Clean and inspect caliper mating surface
   Using brake parts cleaner and wire brush, thoroughly clean EPB motor mounting surface on caliper housing. Remove all dirt, rust, and old grease from motor shaft bore. Inspect O-ring groove (if equipped) for damage. Verify caliper piston mechanism moves freely by viewing into motor mounting bore - internal threads should be clean and undamaged.
   ℹ️Debris or corrosion in motor mounting area will cause premature EPB motor failure and binding.
8. 8

   Install new EPB motor O-ring seal
   If new EPB motor includes replacement O-ring or seal, remove old seal from caliper housing groove and clean groove thoroughly. Lightly lubricate new O-ring with clean brake fluid and install into groove on caliper housing. Ensure O-ring is seated properly without twisting.
   ⚠Use only brake fluid or approved silicone grease on O-ring. Petroleum-based lubricants will damage rubber seals.
9. 9

   Install new EPB motor
   Align new EPB motor shaft with caliper piston mechanism. Motor shaft has gear teeth that must mesh with internal piston threads. Carefully insert motor straight into housing while slowly rotating motor clockwise and counterclockwise to engage gears. Once fully seated, motor mounting surface should be flush with caliper housing. Install both mounting bolts and hand-tighten.
   ⚠Do not force motor installation. Gear teeth must mesh naturally - forcing will damage internal caliper mechanism.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
10. 10

    Reconnect EPB motor electrical connector
    Connect wiring harness to new EPB motor. Ensure connector clicks fully into place and locking tab engages. Gently tug connector to verify secure connection. Route wiring away from moving suspension components and heat sources.
11. 11

    Reinstall brake pads and hardware
    Clean caliper bracket with wire brush and brake cleaner. Reinstall anti-rattle clips and pad hardware in original positions. Apply thin coat of high-temp brake grease to pad hardware contact points (not friction surfaces). Slide brake pads back into caliper bracket in correct orientation.
12. 12

    Reinstall brake caliper
    Remove caliper from hanger. Clean caliper slide pins and bores with brake cleaner. Apply silicone brake grease to slide pins as specified. Position caliper over brake pads and rotor. Install both caliper slide pin bolts and torque to specification in a crossing pattern.
    ℹ️Caliper must move freely on slide pins for proper brake function. Verify caliper slides smoothly before final torquing.
    Torque spec

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

    Calibrate EPB system with scan tool
    Reconnect negative battery cable. Turn ignition to ON position. Using scan tool, navigate to EPB calibration or learn procedure. Follow scan tool prompts to calibrate new EPB motor - this typically involves automated extension and retraction cycles. System will set proper piston position and store motor parameters. Scan tool will confirm successful calibration. Do not interrupt calibration process.
    ⚠️EPB system WILL NOT function correctly without proper calibration. Vehicle parking brake will be inoperative until calibration completes successfully.
    ⚠Motor will operate during calibration - keep hands and tools clear of caliper area.
14. 14

    Test EPB operation
    With scan tool still connected, use EPB apply/release functions to cycle parking brake 3-5 times. Verify motor operates smoothly without unusual noises. Monitor scan tool for any fault codes. Turn ignition OFF, then use cab EPB switch to apply and release parking brake - verify indicator light operates correctly and system responds to switch commands.
15. 15

    Reinstall wheel and perform final checks
    Reinstall wheel onto hub. Install lug nuts and hand-tighten in star pattern. Lower vehicle until tire just contacts ground (weight still on jack stands). Torque lug nuts to specification in star pattern. Fully lower vehicle and remove jack stands. Perform final lug nut torque verification in star pattern.
    ℹ️Re-torque wheel lug nuts after 50-100 miles of driving.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Reassembly is covered in main procedure steps as this is a component replacement job.
2. Ensure all electrical connections are secure and wiring is properly routed away from heat and moving parts.
3. Verify brake fluid level in master cylinder reservoir is at MAX line - top off with Motorcraft DOT 4 LV if needed.
4. Clear any stored fault codes from EPB module using scan tool after successful calibration.

Verification

• With engine running and vehicle on level ground, apply EPB using cab switch - verify yellow indicator light illuminates and audible motor operation is smooth.
• Release EPB with brake pedal depressed - verify indicator light extinguishes and motor releases.
• Perform parking brake holding test: With vehicle on slight incline (if safe area available), apply EPB and shift to neutral - vehicle should not roll.
• Test drive vehicle at low speed in safe area - apply and release EPB multiple times, verify normal brake pedal feel and no warning lights.
• Scan EPB system for fault codes - confirm no codes present and system shows 'ready' status.
• Check brake fluid level again after test drive - level should remain at MAX with no leaks visible at caliper.
• Verify parking brake holds vehicle securely on incline before returning to normal service.

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