Brake Rotors - Rear Pair

Replacement of rear brake rotors on a 2015-2020 Ford F-150 with 5.0L V8, including caliper removal, rotor replacement, and proper torque specifications.

Warnings

Tools required

Parts

• Rear brake rotors × 2 — Use OEM specification or equivalent
• Rotor set screws (if corroded) × 2 — M6 x 1.0 x 10mm

Fluids

• Motorcraft DOT 4 LV Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on level, solid ground and engage parking brake
2. Loosen rear wheel lug nuts 1/4 turn while vehicle is on ground
3. Raise rear of vehicle with floor jack and secure on jack stands at manufacturer-specified lift points on frame
4. Remove rear wheels completely and set aside
5. Inspect brake fluid reservoir level under hood - if low, top off with Motorcraft DOT 4 LV brake fluid before beginning
6. Clean brake assembly area with brake parts cleaner to prevent contamination

Procedure

1. 1

   Remove caliper slide pin bolts
   Locate the two caliper slide pin bolts on the rear of the caliper. Using a socket and breaker bar, remove both caliper slide pin bolts. These bolts allow the caliper to pivot and will be reused with fresh silicone brake grease applied.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
2. 2

   Remove brake caliper
   Carefully pivot the caliper upward and off the brake pads and rotor. 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 weight on the brake hose.
   ⚠️Never let the caliper hang by the brake hose. The weight can damage the internal hose structure, leading to brake failure.
3. 3

   Remove brake pads and clips
   Remove the brake pads from the caliper bracket. Note the orientation and position of any anti-rattle clips or shims for reassembly. Set pads aside if reusing, or discard if replacing. Remove any pad retention clips from the bracket.
   ℹ️Take photos of pad and clip orientation before removal to ensure correct reassembly.
4. 4

   Remove caliper bracket
   Locate the two large caliper bracket bolts that secure the bracket to the axle housing. These are larger than the slide pin bolts. Using a breaker bar and socket, remove both caliper bracket bolts. Remove the bracket completely and set aside.
   Torque spec

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

   Remove rotor set screws
   Using a T30 Torx bit, remove the rotor set screw(s) securing the rotor to the hub. These screws are often corroded and may strip. Apply penetrating oil if necessary and use firm pressure. If stripped, they can be drilled out - replacement screws are inexpensive.
   ⚠Set screws are often corroded. Apply penetrating oil and allow to soak before removal to prevent stripping.
   Torque spec

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

   Remove old rotor
   Pull the rotor straight off the hub. If the rotor is stuck due to corrosion, use a rubber mallet to tap around the outer edge and hub hat area. Do not strike the rotor friction surface. If severely corroded, thread bolts into the threaded holes on the rotor face (if equipped) to push the rotor off.
   ⚠Rotors may be heavy and have sharp edges. Use gloves and maintain secure grip during removal.
7. 7

   Clean hub mounting surface
   Using a wire brush, thoroughly clean the hub face where the rotor mounts. Remove all rust, corrosion, and debris. The hub surface must be clean and flat to prevent rotor runout and pulsation. Clean the hub pilot (center ring) as well.
   ℹ️A clean hub surface is critical for proper rotor seating. Any debris or corrosion will cause rotor wobble and brake pulsation.
8. 8

   Install new rotor
   Remove any protective coating from the new rotor using brake parts cleaner. Wipe both rotor surfaces clean and dry. Slide the new rotor onto the hub, ensuring it seats flush against the hub face. Rotate the rotor to align the set screw hole with the hub hole.
   ⚠New rotors have a protective oil coating that must be removed with brake cleaner. Failure to remove this coating will contaminate brake pads and cause poor braking performance.
9. 9

   Install rotor set screws
   Install the rotor set screw(s) and torque to specification using a T30 Torx bit and torque wrench. These screws only hold the rotor during assembly - the wheel clamping force holds the rotor during operation. Do not overtighten.
   Torque spec

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

    Reinstall caliper bracket
    Position the caliper bracket over the new rotor and align with the mounting holes on the axle housing. Install both caliper bracket bolts and torque to specification in a crisscross pattern. Ensure the bracket is seated properly before final torque.
    Torque spec

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

    Install brake pads and clips
    Reinstall any anti-rattle clips or shims to the caliper bracket in their original positions. Install the inner and outer brake pads into the bracket, ensuring they are properly seated in the clips. Verify pads move freely in the bracket.
    ℹ️If installing new brake pads with new rotors, ensure pad material is compatible with rotor specification.
12. 12

    Compress caliper piston
    Before installing the caliper over the new pads, the caliper piston must be compressed to accommodate the thicker new rotor and pads. Use a C-clamp or brake caliper piston tool to slowly compress the piston into the caliper bore. Monitor the brake fluid reservoir - it will rise as the piston compresses. Remove excess fluid if necessary to prevent overflow.
    ⚠As the piston is compressed, brake fluid will be pushed back into the reservoir and may overflow. Check the reservoir and remove fluid if near the MAX line.
13. 13

    Reinstall brake caliper
    Remove the caliper from its support wire. Clean the caliper slide pin bores in the bracket with brake parts cleaner. Apply a thin coat of silicone brake grease to the slide pin bolts (not the threads). Position the caliper over the brake pads and rotor. Install both caliper slide pin bolts and torque to specification.
    ⚠Use only silicone brake grease on slide pins. Do not use petroleum-based grease, which will damage rubber boots and seals.
    Torque spec

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)
14. 14

    Reinstall wheels
    Clean the wheel mounting surface on the hub with a wire brush. Install the rear wheels and hand-tighten all lug nuts. Lower the vehicle until the tire just touches the ground (but vehicle weight is still on jack stands). Torque the lug nuts to specification in a star pattern. Fully lower the vehicle and perform a final torque check on all lug nuts.
    Torque spec

    Wheel Lug Nuts203 Nm (150 lb-ft)

Reassembly

1. Repeat all steps for the opposite rear wheel to replace both rear rotors
2. Before moving the vehicle, pump the brake pedal several times until it feels firm and normal - the first press will go to the floor as the caliper pistons re-extend
3. Check brake fluid level in the reservoir under the hood and top off with Motorcraft DOT 4 LV brake fluid if needed
4. Verify all tools and parts have been removed from under the vehicle

Verification

• Start the engine and pump the brake pedal - it should feel firm with normal travel. If the pedal feels soft or goes to the floor, DO NOT DRIVE the vehicle
• Check for any brake fluid leaks around the calipers, brake lines, and reservoir
• Perform a low-speed test drive in a safe area - brake gently at first to verify proper operation and bedding of new rotors
• Listen for any abnormal noises such as grinding, squealing, or rubbing during the test drive
• Verify that the vehicle brakes straight without pulling to either side
• After 50-100 miles of normal driving, re-torque wheel lug nuts to specification
• New rotors may require a bedding-in period - expect reduced initial braking performance for the first 100-200 miles as pads conform to rotors

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