Replacement of the front brake caliper on a 2021-2024 Ford F-150 with 3.5L EcoBoost engine, including brake line disconnection, caliper removal, installation, and system bleeding.

Warnings

Tools required

Parts

• Front brake caliper assembly × 1 — Use OEM specification
• Copper crush washers for brake line banjo bolt × 2 — 2 washers per banjo bolt
• Brake pads (if reusing caliper bracket) × 1 — Use OEM specification

Fluids

• Motorcraft DOT 4 LV Brake Fluid — 1 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks behind rear wheels
3. Using turkey baster or syringe, remove approximately half the brake fluid from the master cylinder reservoir to prevent overflow during caliper compression
4. Loosen front wheel lug nuts while vehicle is on ground (do not remove)
5. Lift front of vehicle with floor jack and secure on jack stands rated for vehicle weight at manufacturer-specified lift points
6. Remove front wheel completely
7. Verify you have new copper crush washers and all required tools before beginning disassembly

Procedure

1. 1

   Clean brake caliper area
   Spray brake cleaner on the caliper, brake line connection, and mounting bolts to remove dirt and corrosion. This prevents contamination when opening the brake system and makes fastener removal easier. Allow cleaner to dry completely.
2. 2

   Disconnect brake hose from caliper
   Place drain container under brake line connection. Using a line wrench on the banjo bolt at the caliper, loosen and remove the brake hose banjo bolt. Be prepared for brake fluid spillage. Remove and discard the two copper crush washers (one on each side of the banjo fitting). Immediately plug the brake line opening with a clean rubber cap or wrap in plastic to prevent fluid loss and contamination.
   ⚠Brake fluid will drain from the line and caliper. Have container ready and clean spills immediately to prevent paint damage.
3. 3

   Remove caliper mounting bolts
   Locate the two caliper slide bolts on the rear of the caliper (typically 18mm). Using a socket wrench, remove both caliper mounting bolts completely. The caliper is now free from the bracket but still contains the brake pads.
4. 4

   Remove old caliper
   Carefully lift the caliper off the brake rotor and bracket. The brake pads may come with the caliper or remain in the bracket. Remove the caliper completely from the vehicle. If the caliper is being replaced due to failure, inspect the brake pads for contamination from leaking brake fluid - contaminated pads must be replaced.
5. 5

   Inspect and prepare caliper bracket
   With caliper removed, inspect the caliper bracket for damage, corrosion, or wear on the pad slide surfaces. If installing a new caliper that did not come with a bracket, you will reuse the existing bracket (leave it mounted). Clean the bracket slide surfaces with brake cleaner. If brake pads are being reused, ensure they slide freely in the bracket channels.
6. 6

   Prepare new caliper
   Remove the new caliper from packaging. Verify the bleeder screw is present and closed (turned clockwise). If the caliper comes with a dust cap on the brake line port, remove it. Do not compress the new caliper pistons yet - they should be in the retracted position for installation.
7. 7

   Install brake pads in bracket
   If brake pads were removed, install them into the caliper bracket now. Ensure the pad wear indicators are positioned correctly (typically on the inner pad, facing the correct direction per manufacturer specification). Pads should slide freely but snugly in the bracket channels.
8. 8

   Install new caliper onto bracket
   Carefully position the new caliper over the brake rotor and pads, aligning the caliper slide pin holes with the bracket. Ensure the brake line port is accessible and positioned toward the vehicle's brake line. The caliper should slide onto the bracket easily - do not force it.
9. 9

   Install and torque caliper mounting bolts
   Apply a small amount of medium-strength thread locker to the threads of both caliper mounting bolts. Insert both bolts and hand-tighten them first. Using a torque wrench, tighten both caliper mounting bolts to specification (101-102 Nm / 75 lb-ft). Verify the caliper is secure and properly seated on the bracket.
   ℹ️Thread locker is essential for caliper bolts to prevent loosening from vibration during operation.
10. 10

    Connect brake hose to new caliper
    Remove the plug or covering from the brake line. Install one NEW copper crush washer onto the banjo bolt, then insert the banjo fitting into the caliper port, followed by the second NEW copper crush washer. Thread the banjo bolt by hand first to ensure proper alignment. Using a torque wrench, tighten the brake hose banjo bolt to 47 Nm (35 lb-ft). Do not overtighten.
    ⚠Always use NEW copper crush washers. Reusing old washers will cause brake fluid leaks and system failure.
11. 11

    Bleed the brake caliper
    Fill the master cylinder reservoir to the MAX line with fresh DOT 4 LV brake fluid. Attach clear tubing to the bleeder screw on the caliper and submerge the other end in a container with clean brake fluid. Have a helper pump the brake pedal 3-4 times and hold pressure, then open the bleeder screw 1/4 turn. Fluid and air will flow into the container. Close the bleeder before the pedal reaches the floor. Repeat until no air bubbles appear in the tubing (typically 5-10 repetitions). Tighten bleeder screw to specification. Check master cylinder level frequently and maintain at MAX line.
    ⚠️Air in the brake system will cause brake failure. Continue bleeding until absolutely no air bubbles are visible in the discharge tubing.
    ⚠Never let the master cylinder run dry during bleeding or air will enter the entire system requiring ABS module bleeding.
    Torque spec

    Bleeder Screw10 Nm (7 lb-ft)
12. 12

    Inspect for leaks
    With the bleeder screw tightened, have your helper apply firm pressure to the brake pedal and hold for 30 seconds. Carefully inspect the banjo bolt connection and bleeder screw for any signs of brake fluid leakage. Also check around the caliper body for signs of leaking. Any leakage requires immediate correction before proceeding.
    ⚠️Any brake fluid leakage indicates improper installation. Do not drive the vehicle until all leaks are eliminated.
13. 13

    Reinstall wheel
    Clean the wheel hub surface and wheel mounting surface with a wire brush. Position the wheel onto the hub and hand-thread all lug nuts. Using a torque wrench in a star/cross pattern, torque all lug nuts to 156 Nm (115 lb-ft) in three progressive steps (50%, 75%, 100% of final torque).
14. 14

    Lower vehicle and final checks
    Lower the vehicle from jack stands to the ground using the floor jack. Remove the jack stands and fully lower the vehicle. With the vehicle on the ground, re-torque the wheel lug nuts to 156 Nm (115 lb-ft) in a star pattern to ensure proper seating. Check the master cylinder reservoir and fill to MAX line with DOT 4 LV brake fluid if needed.

Reassembly

1. Ensure master cylinder reservoir is filled to MAX line with fresh DOT 4 LV brake fluid
2. Clean any brake fluid spills from vehicle components, brake rotor, and paint surfaces immediately
3. If only one caliper was replaced, verify brake pull by testing in a safe area - unequal braking may indicate the opposite caliper needs service
4. Dispose of old brake fluid and contaminated materials according to local environmental regulations

Verification

• With engine off, pump brake pedal several times - pedal should become firm and maintain height. Soft or spongy pedal indicates air in the system requiring additional bleeding
• Start the engine and apply firm brake pressure - pedal should remain firm and not slowly sink to the floor. Sinking pedal indicates a leak or air in the system
• Visually inspect the caliper, banjo bolt connection, and bleeder screw for any signs of fluid leakage while helper applies brake pressure
• Check master cylinder reservoir level - it should be at MAX line and fluid should be clear, not contaminated
• Perform a low-speed test drive in a safe area (empty parking lot) - brakes should engage smoothly without pulling to one side
• After test drive, re-inspect all connections for leaks and verify brake pedal remains firm
• After 50-100 miles of driving, re-torque wheel lug nuts to 156 Nm (115 lb-ft) to ensure proper wheel seating

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