This procedure covers replacement of a single front brake rotor on a 2015-2020 Ford F-150 with 5.0L V8 engine, including caliper removal, rotor replacement, and proper torque specifications.

Warnings

Tools required

Parts

• Front brake rotor × 1 — Use OEM specification or quality aftermarket equivalent
• Rotor set screw (if corroded) × 1 — M6 x 1.0 x 10mm

Preparation

1. Park vehicle on level, solid ground and engage parking brake
2. Place wheel chocks behind rear wheels
3. Loosen front wheel lug nuts 1/4 turn while wheel is still on ground
4. Lift front of vehicle with floor jack at manufacturer-specified jacking point
5. Place jack stands under frame rails and lower vehicle onto stands
6. Remove wheel completely and set aside
7. Inspect brake system for fluid leaks, damaged hoses, or excessive pad wear before proceeding

Procedure

1. 1

   Compress brake caliper piston
   Before removing the caliper, slowly compress the caliper piston using a C-clamp or brake caliper piston tool. Place the clamp on the back of the caliper body and against the outboard brake pad. Compress slowly to push brake fluid back into the master cylinder reservoir. This makes caliper removal easier and prevents brake fluid overflow.
   ⚠Do not compress the piston with the bleeder screw open, as this can introduce air into the brake system.
2. 2

   Remove caliper slide pin bolts
   Using an 18mm socket or wrench, remove the two caliper slide pin bolts located on the back side of the caliper. These are the smaller bolts that allow the caliper to slide. Keep track of these bolts as they will be reused.
   Torque spec

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

   Remove and support brake caliper
   Carefully lift the caliper assembly off the rotor and bracket. Do NOT disconnect the brake hose. Immediately support the caliper using wire or a bungee cord attached to the suspension or frame. Ensure there is no tension or stress on the brake hose. Do not allow caliper to hang freely.
   ⚠️Allowing the caliper to hang by the brake hose can cause internal hose damage, leading to brake failure.
4. 4

   Remove caliper bracket bolts
   Using a 21mm socket, remove the two large caliper bracket bolts that secure the bracket to the steering knuckle. These bolts require significant force to remove. Once removed, lift the caliper bracket away from the rotor.
   Torque spec

   Bracket Bolts127 Nm (94 lb-ft)
5. 5

   Remove rotor set screw
   Using a T30 Torx bit, remove the rotor set screw that secures the rotor to the hub. If the screw is corroded or stripped, it may need to be drilled out. Apply penetrating oil if the screw is stuck and allow to soak for several minutes.
   ℹ️If the set screw is severely corroded, it is acceptable to drill it out carefully. This screw primarily aids in assembly and is not critical to rotor retention once lug nuts are torqued.
   Torque spec

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

   Remove old brake rotor
   Pull the rotor straight off the wheel hub. If the rotor is stuck due to corrosion, tap it gently from behind with a rubber mallet, alternating sides. Do not strike the rotor face or use excessive force. If extremely stuck, spray penetrating oil around the hub center and wait before attempting removal again.
7. 7

   Clean hub surface
   Using a wire brush, thoroughly clean the hub face and hub pilot diameter where the rotor mounts. Remove all rust, corrosion, and debris. The hub surface must be clean and flat to prevent rotor runout and brake pulsation. Wipe clean with brake cleaner.
8. 8

   Prepare new rotor
   Remove new rotor from packaging. Clean both friction surfaces thoroughly with brake cleaner to remove any protective coating or oil. Wipe dry with a clean, lint-free cloth. If desired, apply a thin coating of anti-seize to the hub pilot diameter and center hole (avoid getting any on friction surfaces).
   ⚠Any oil, grease, or protective coating left on the rotor friction surfaces will cause severe brake noise and reduced braking performance.
9. 9

   Install new rotor
   Slide the new rotor onto the hub, aligning the set screw hole. Ensure the rotor sits flush against the hub face with no gaps or interference. Install the rotor set screw and tighten to specification using the T30 Torx bit.
   Torque spec

   Rotor Set Screws8 Nm (6 lb-ft)
10. 10

    Reinstall caliper bracket
    Position the caliper bracket over the rotor and align bolt holes with the steering knuckle. If recommended by the torque specification, apply medium-strength thread locker to the caliper bracket bolt threads. Install both bracket bolts and torque to specification in an alternating pattern.
    Torque spec

    Bracket Bolts127 Nm (94 lb-ft)
11. 11

    Inspect and lubricate slide pins
    Before reinstalling the caliper, inspect the slide pins for damage, corrosion, or torn boots. Clean the slide pins and apply fresh silicone brake grease to the pin surfaces and boots. Ensure slide pins move freely in the bracket.
12. 12

    Reinstall brake caliper
    Remove the support wire/bungee cord from the caliper. Position the caliper over the brake pads and rotor. Align the slide pin bolt holes and install both slide pin bolts. Apply silicone brake grease to the bolt threads as specified. Torque slide pin bolts to specification.
    Torque spec

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

    Reinstall wheel
    Place wheel onto hub and hand-thread all lug nuts. Lower vehicle slightly so wheel contacts ground but vehicle weight is still on jack stands. Torque lug nuts to specification in a star pattern to ensure even seating.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)
14. 14

    Lower vehicle and final checks
    Raise vehicle slightly, remove jack stands, and lower vehicle completely to ground. With vehicle on ground, re-torque lug nuts in star pattern to verify proper torque. Pump brake pedal several times until firm pedal is achieved before attempting to move vehicle.
    ⚠️Do not move vehicle until brake pedal is firm. Pumping the pedal repositions the caliper piston against the new rotor.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. All torque specifications must be followed exactly as listed to ensure proper brake system function
2. Star pattern tightening of lug nuts prevents wheel runout and uneven rotor wear
3. Caliper slide pins must move freely with proper lubrication to allow even pad wear

Verification

• Pump brake pedal 5-10 times and verify firm pedal feel before driving
• Check brake fluid level in master cylinder reservoir and top off if needed with Motorcraft DOT 4 LV brake fluid
• Perform test stops at low speed (5-10 mph) in a safe area to verify proper brake function before returning to normal driving
• Listen for any unusual noises during initial test stops - minor squeaking during break-in is normal, but grinding or scraping indicates a problem
• Perform 20-30 moderate stops from 30-40 mph to properly bed in the new rotor (avoid hard braking during first 200 miles)
• Visually inspect wheel area for any brake fluid leaks after test drive
• Re-check lug nut torque after driving 50-100 miles

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