This procedure covers the complete disassembly, cleaning, inspection, and rebuild of the front brake calipers on a 2015-2020 Ford F-150 with 5.0L V8 engine using new seals and hardware.

Warnings

Tools required

Parts

• Front brake caliper rebuild kit (seals, dust boots, O-rings) × 2 — Use OEM specification - Ford Motorcraft or equivalent
• Brake fluid × 1 — Motorcraft DOT 4 LV
• Caliper slide pin boots and hardware kit × 2 — Often included in rebuild kit
• Copper crush washers for brake line banjo bolts × 2 — Use OEM specification

Fluids

• Motorcraft DOT 4 LV Brake Fluid — 1 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen front wheel lug nuts while vehicle is on ground, but do not remove
3. Raise front of vehicle with floor jack and support securely on jack stands positioned at factory lift points on frame
4. Remove front wheels completely
5. Verify adequate workspace and lighting for detailed rebuild work
6. Open brake fluid reservoir and check fluid level - mark current level for reference
7. Place absorbent material and drain pan under work area to catch brake fluid spills
8. Have all rebuild kit components unpacked and inspected before beginning disassembly

Procedure

1. 1

   Remove caliper from vehicle
   Using a brake line wrench, loosen the brake line banjo bolt at the caliper inlet while holding a catch container beneath to capture brake fluid. Remove the banjo bolt completely and immediately plug the brake line with a rubber cap or clean rag to prevent fluid loss and contamination. Remove the two caliper slide pin bolts using appropriate socket. Lift caliper assembly away from rotor and brake pads. Note the position of brake pads and hardware for reference.
   Torque spec

   Line Fittings26 Nm (19 lb-ft)
2. 2

   Remove caliper bracket (if rebuilding includes bracket service)
   Remove the two caliper bracket mounting bolts that secure the bracket to the steering knuckle. These are large bolts requiring significant torque to remove. Use penetrating oil if needed. Remove bracket and set aside for cleaning. If bracket slide pins show wear or corrosion, they should be cleaned and re-greased or replaced.
   Torque spec

   Bracket Bolts127 Nm (94 lb-ft)
3. 3

   Remove piston from caliper body
   Place several clean rags or a wood block inside the caliper to catch the piston. Apply low-pressure compressed air (20-30 PSI maximum) to the brake fluid inlet port on the caliper. The piston will slowly eject - keep fingers clear and control ejection with the wood block. If piston is seized, tap caliper body gently with plastic mallet while applying air pressure. Once piston begins moving, remove air and extract piston by hand if possible. Never place fingers in front of piston during air ejection.
   ⚠️Keep hands and fingers away from piston path. Use wood block to control piston ejection. Excessive air pressure can cause violent piston ejection resulting in serious injury.
4. 4

   Remove piston seal and dust boot
   Remove the outer dust boot from the caliper bore groove using a plastic or brass pick - avoid scratching the bore. Carefully pry out the square-cut piston seal from its groove inside the caliper bore using a plastic pick. Never use metal tools that could scratch or gouge the precision bore surface. Inspect the bore carefully for any scoring, pitting, or corrosion. Minor staining is acceptable, but any scratches or pits deeper than 0.001 inch require caliper replacement.
   ⚠Do not use metal tools on caliper bore. Any scratches or gouges in the bore will cause seal failure and brake fluid leaks.
5. 5

   Clean and inspect caliper components
   Thoroughly clean the caliper bore, piston, and all caliper passages using brake parts cleaner and lint-free rags. Clean the brake fluid inlet port and bleeder screw threads. Remove the bleeder screw and clean thoroughly - replace if damaged or corroded. Inspect piston for chrome plating damage, corrosion, scoring, or pitting. Any piston damage requires replacement. Inspect caliper bore for corrosion or scoring - bore must be smooth and free of defects. Clean caliper bracket and slide pins thoroughly with wire brush and brake cleaner.
   Torque spec

   Bleeder Screw10 Nm (7 lb-ft)
6. 6

   Lubricate and install new piston seal
   Coat the new square-cut piston seal from the rebuild kit with clean DOT 4 LV brake fluid. Carefully install the seal into its groove in the caliper bore, ensuring it seats completely around the entire circumference without twisting. The seal must sit flat in the groove with no raised sections. Coat the caliper bore with clean brake fluid.
   ℹ️Use only clean brake fluid from a sealed container for lubrication. Never reuse old brake fluid or use petroleum-based lubricants on brake seals.
7. 7

   Install piston and dust boot
   Coat the new piston (or cleaned original if in perfect condition) completely with clean DOT 4 LV brake fluid. Carefully insert the piston into the caliper bore, ensuring it enters straight without cocking to one side. Push piston in by hand until it contacts the seal. Install the new dust boot into the groove on the piston first, then carefully seat the outer edge of the boot into the caliper body groove. Ensure boot is properly seated all the way around. Push piston fully into bore - it should move smoothly with moderate hand pressure.
   ⚠Piston must enter bore perfectly straight. Cocking the piston can damage the seal or bore. If resistance is felt, remove piston and restart.
8. 8

   Service caliper slide pins and bracket
   Remove slide pins from caliper bracket. Clean pins thoroughly with brake cleaner and inspect for wear, corrosion, or damage. Inspect slide pin boots for tears or deterioration - replace if damaged. Clean slide pin bores in bracket. Apply thin coat of silicone brake caliper grease to slide pins (not petroleum grease). Install new slide pin boots if included in kit. Insert pins into bracket and verify smooth movement. Apply silicone brake grease to bracket contact points where pads slide.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
9. 9

   Reinstall caliper bracket to knuckle
   Position caliper bracket onto steering knuckle. Install both bracket mounting bolts and hand-tighten. Apply threadlocker to bracket bolt threads as recommended. Using torque wrench, tighten bracket bolts to specification in a cross pattern. Verify bracket is secure and properly seated against knuckle mounting surface.
   Torque spec

   Bracket Bolts127 Nm (94 lb-ft)
10. 10

    Install brake pads and caliper assembly
    Install brake pad anti-rattle clips and hardware onto bracket if removed. Install inner and outer brake pads into bracket, ensuring they are properly positioned in the hardware. Position rebuilt caliper over brake pads and align slide pin holes. Install slide pin bolts with silicone brake grease on bolt threads and torque to specification. Caliper should move smoothly on slide pins.
    Torque spec

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

    Reconnect brake line
    Remove plug from brake line. Install new copper crush washers on both sides of the banjo bolt fitting (never reuse old washers). Position brake line banjo fitting onto caliper inlet port. Install banjo bolt with new washers and hand-tighten. Using brake line wrench and torque wrench, tighten banjo bolt to specification. Do not overtighten as this can damage the fitting.
    ⚠Always use new copper crush washers. Reusing old washers will cause brake fluid leaks and system failure.
    Torque spec

    Line Fittings26 Nm (19 lb-ft)
12. 12

    Bleed brake caliper
    Fill brake fluid reservoir to MAX line with fresh Motorcraft DOT 4 LV brake fluid. Attach clear hose to bleeder screw and place other end in container with small amount of brake fluid. Have assistant pump brake pedal 5-10 times and hold pressure. Open bleeder screw 1/4 turn while pedal is held down - fluid and air will discharge. Close bleeder before pedal reaches floor. Repeat process until no air bubbles appear in discharge fluid and pedal feels firm. Tighten bleeder screw to specification on final closure. Top off reservoir to MAX line.
    ⚠️Never allow brake fluid reservoir to run dry during bleeding. Air entering the system can require complete system bleeding and may reach ABS module.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
13. 13

    Repeat procedure for opposite side
    Perform steps 1-12 for the opposite front caliper. Working on one caliper at a time ensures you maintain brake system integrity and have a reference for proper assembly. After both calipers are rebuilt, check brake fluid level and top off to MAX line with fresh DOT 4 LV fluid.
    ℹ️Complete one full caliper rebuild before starting the second side to maintain system reference and minimize brake system open time.
14. 14

    Reinstall wheels and perform final checks
    Reinstall front wheels and hand-tighten lug nuts in star pattern. Lower vehicle to ground. Torque wheel lug nuts to specification in star pattern using torque wrench. Pump brake pedal slowly until firm resistance is felt - pedal should not sink to floor. Check all brake line connections and caliper areas for any signs of brake fluid leakage. Inspect brake fluid reservoir level and top off if needed.
    ⚠️Do not drive vehicle until brake pedal is firm and all brake fluid leaks are corrected. A soft pedal indicates air in system or brake failure.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Ensure all caliper bolts are torqued to proper specification with appropriate threadlocker or grease as specified
2. Verify brake fluid level is at MAX line in reservoir using only fresh Motorcraft DOT 4 LV brake fluid
3. Check that all brake line connections are tight and show no signs of leakage
4. Confirm brake pedal feels firm and does not sink when constant pressure is applied
5. Verify wheel lug nuts are torqued in proper star pattern to specification

Verification

• With engine off, pump brake pedal multiple times - pedal should become firm and maintain height without sinking
• Start engine and verify brake pedal height remains consistent with increased pedal assist
• Inspect all caliper mounting points, slide pins, and brake line connections for any signs of fluid leakage
• Check brake fluid reservoir level - should be at MAX line with no signs of aeration or bubbles in fluid
• Perform low-speed test drive in safe area - brakes should apply smoothly and evenly without pulling to either side
• After test drive, re-inspect all connections for leaks and verify brake pedal remains firm
• Check wheel lug nut torque after 50-100 miles of driving
• Monitor brake performance over next several days - any soft pedal, pulling, or unusual noises require immediate inspection

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