Brake Caliper Rebuild - Rear

This procedure covers disassembly, cleaning, inspection, seal replacement, and reassembly of the rear brake calipers on a 2015-2020 Ford F-150 with 5.0L V8 engine.

Warnings

Tools required

Parts

• Rear brake caliper rebuild kit (includes pistons, seals, dust boots, hardware) × 2 — Use OEM Ford specification or quality aftermarket equivalent
• Silicone brake grease (high-temperature) × 1 — Motorcraft compatible brake lubricant
• Medium-strength threadlocker × 1 — Loctite 243 or equivalent
• Copper crush washers for brake line banjo bolts (if disconnecting lines) × 4 — Use OEM specification

Fluids

• Motorcraft DOT 4 LV Brake Fluid — 1 qt

Preparation

1. Park vehicle on level surface and chock front wheels securely
2. Loosen rear wheel lug nuts while vehicle is on ground but do not remove
3. Safely raise rear of vehicle and support on jack stands rated for vehicle weight at manufacturer-specified jacking points
4. Remove rear wheels completely
5. Use turkey baster or fluid siphon to remove approximately half the brake fluid from master cylinder reservoir to prevent overflow during caliper piston compression
6. Have clean brake fluid catch container and all tools ready before beginning disassembly

Procedure

1. 1

   Remove rear brake caliper assembly
   If rebuilding without disconnecting brake lines, remove caliper slide pin bolts and support caliper with wire hanger to avoid stressing brake hose. If disconnecting brake lines (recommended for thorough rebuild), use line wrench to loosen brake line fitting at caliper before removing caliper bolts. Remove caliper slide pin bolts and remove caliper from rotor and bracket. If brake line was disconnected, immediately plug line and caliper port to prevent fluid loss and contamination.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)

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

   Remove brake pads and inspect hardware
   Remove brake pads from caliper bracket. Inspect caliper bracket slide pins and hardware for wear, damage, or corrosion. Clean bracket thoroughly with brake parts cleaner and wire brush. Set aside for reinstallation. Take photos of hardware orientation for reference during reassembly.
   ℹ️Mark left and right calipers clearly to avoid mixing components during rebuild.
3. 3

   Disassemble caliper and remove piston
   Place caliper on clean work surface with piston facing up. Remove dust boot retaining ring if present. For integrated parking brake calipers, use piston wind-back tool to carefully rotate and extract piston counterclockwise while pulling outward. Apply controlled compressed air (maximum 30 psi) to fluid inlet port if piston is difficult to remove, covering with shop towel to control piston ejection. Remove dust boot completely once piston is extracted.
   ⚠Do not use high-pressure air. Uncontrolled piston ejection can cause serious injury. Keep fingers clear of piston path.
4. 4

   Remove piston seal and clean caliper bore
   Use plastic or wooden pick to carefully extract piston seal from groove in caliper bore. Do not use metal tools that can scratch the bore surface. Thoroughly clean caliper bore, piston, and all internal passages with brake parts cleaner. Dry completely with lint-free rags and compressed air. Clean parking brake mechanism components and actuator screw threads.
   ⚠Any scratches in the caliper bore will cause seal failure and brake fluid leaks.
5. 5

   Inspect caliper bore and piston for serviceability
   Carefully inspect caliper bore for pitting, scoring, corrosion, or any surface damage. Use micrometer to measure bore diameter and piston diameter per rebuild kit specifications. Measure in multiple locations and orientations. Inspect piston chrome plating for any peeling, pitting, or wear. Check parking brake actuator threads and mechanism for damage. If any component shows wear beyond specification or surface damage deeper than 0.001 inch, caliper must be replaced rather than rebuilt.
   ⚠Do not attempt to rebuild calipers with damaged bores or pistons. Failure is certain and will result in brake system malfunction.
6. 6

   Install new piston seal
   Coat new piston seal from rebuild kit with clean DOT 4 LV brake fluid. Carefully install seal into groove in caliper bore, ensuring it seats properly without twisting. Verify seal is completely seated in groove around entire circumference. Do not use any petroleum-based lubricants which will damage rubber seals.
   ⚠Only use fresh DOT 4 LV brake fluid or silicone brake grease on seals. Petroleum products will cause seal failure.
7. 7

   Install piston and dust boot
   Coat new piston from rebuild kit (or cleaned original if within specification) with clean brake fluid. Align piston slots with parking brake actuator pins inside caliper bore. Carefully rotate piston clockwise while pressing inward, threading it onto parking brake mechanism. Continue rotating and pressing until piston is fully seated and bottomed in bore. Install new dust boot over piston and seat retaining ring into caliper groove, ensuring boot is properly positioned.
   ℹ️Piston must be rotated clockwise during installation to engage parking brake threads. Forcing without rotation will damage mechanism.
8. 8

   Lubricate slide pins and hardware
   Remove caliper slide pins from bracket if not already removed. Clean pins thoroughly with brake parts cleaner and inspect rubber boots for tears or damage. Replace boots if damaged. Apply thin coat of high-temperature silicone brake grease to slide pin shafts (not threads). Reinstall slide pins into caliper bracket with new boots if needed. Apply silicone brake grease to caliper bracket contact points where pads slide.
   ℹ️Do not use excessive grease. Excess can contaminate brake pads and reduce braking effectiveness.
9. 9

   Reinstall caliper assembly to vehicle
   Install brake pads into caliper bracket with anti-rattle clips in correct orientation. Position rebuilt caliper over rotor and align with bracket. Apply medium-strength threadlocker to caliper slide pin bolt threads. Install and hand-tighten caliper slide pin bolts, then torque to specification using silicone brake grease on threads. If brake line was disconnected, connect line using new copper crush washers and torque line fitting to specification.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)

   Line Fittings26 Nm (19 lb-ft)
10. 10

    Bleed brake system
    Attach clear tubing to bleeder screw and submerge other end in brake fluid catch container. Have assistant pump brake pedal 3-4 times and hold pressure. Open bleeder screw 1/2 turn and allow fluid to flow until stream is bubble-free, then close bleeder screw before pedal reaches floor. Repeat process until no air bubbles appear in discharged fluid. Torque bleeder screw to specification. Repeat for opposite side caliper. Check master cylinder fluid level frequently and maintain at MAX line with fresh DOT 4 LV brake fluid.
    ⚠️Never allow master cylinder to run dry during bleeding. This will introduce air into ABS system requiring professional scan tool bleeding procedure.
    ⚠Bleed brakes in sequence: right rear, left rear, right front, left front for this RWD configuration.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
11. 11

    Reinstall wheels and perform final checks
    Reinstall rear wheels and hand-tighten lug nuts in star pattern. Lower vehicle until wheels just contact ground but suspension is not loaded. Torque wheel lug nuts to specification in star pattern. Fully lower vehicle and remove jack stands. Pump brake pedal repeatedly until firm resistance is felt. Check brake fluid level and top off to MAX line with DOT 4 LV fluid. Inspect all connections for leaks.
    ⚠️Do not drive vehicle until brake pedal feels firm and normal. If pedal feels spongy or goes to floor, repeat bleeding procedure.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Torque all fasteners to specified values using calibrated torque wrench
2. Use only new copper crush washers on brake line fittings
3. Apply medium-strength threadlocker to caliper slide pin bolts as specified
4. Ensure all brake hardware is installed in correct orientation matching reference photos
5. Fill master cylinder to MAX line with fresh Motorcraft DOT 4 LV brake fluid only

Verification

• Pump brake pedal 10-15 times and verify firm pedal feel before driving
• Check for brake fluid leaks at caliper connections, bleeder screws, and brake lines
• Verify master cylinder fluid level is at MAX line and cap is secure
• Test parking brake engagement and verify it holds vehicle on incline
• In safe area away from traffic, test brakes at low speed (5-10 mph) to verify proper operation and even braking before normal driving
• Perform 20-30 moderate brake applications from 30 mph to bed in new seals and components
• Re-check all torque specifications and brake fluid level after test drive
• Monitor brake performance and pedal feel for first 100 miles. Any changes indicate potential issues requiring immediate inspection

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