Replace a single front brake rotor on a 2021-2024 Ford F-150 3.5L EcoBoost, including caliper removal, rotor replacement, and proper torque procedures.

Warnings

Tools required

Parts

• Front brake rotor × 1 — Use OEM specification or equivalent meeting Ford specifications
• Rotor set screw (if corroded) × 1 — M6 x 1.0 x 12mm set screw

Fluids

• Motorcraft DOT 4 LV Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on level, solid ground. Engage parking brake and place transmission in Park.
2. Loosen front wheel lug nuts 1/4 turn while vehicle is still on the ground.
3. Lift front of vehicle using floor jack at designated lift points and secure on jack stands rated for vehicle weight.
4. Remove wheel completely and set aside.
5. Inspect brake fluid level in master cylinder reservoir. If near MAX line, siphon out approximately 1/4 cup to prevent overflow during caliper piston compression.
6. Spray caliper bracket bolts and rotor set screw with penetrating oil if corrosion is present. Allow 10-15 minutes to penetrate.

Procedure

1. 1

   Remove caliper slide pin bolts
   Locate the two caliper slide pin bolts on the rear of the caliper assembly. Use a 15mm socket to remove both slide pin bolts completely. The caliper can now pivot upward. If caliper does not move freely, check that both bolts are fully removed.
   Torque spec

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

   Support and secure caliper
   Carefully lift the caliper assembly up and away from the rotor. Do NOT allow it to hang by the brake hose. Use wire, a bungee cord, or a suitable hook to suspend the caliper from the suspension or frame. Ensure there is no tension or strain on the brake hose.
   ⚠️Caliper must be fully supported. Brake hose damage from hanging weight can cause brake failure.
3. 3

   Remove caliper bracket bolts
   Locate the two large caliper bracket bolts that secure the bracket to the steering knuckle. These are 18mm bolts located behind where the caliper was mounted. Use an 18mm socket with a breaker bar if needed, and remove both bracket bolts completely. Remove the bracket assembly and set aside with brake pads.
   Torque spec

   Bracket Bolts117 Nm (86 lb-ft)
4. 4

   Remove rotor set screw
   Locate the T30 Torx set screw on the face of the rotor (typically located between two of the wheel studs). Use a T30 Torx bit to remove the set screw. If severely corroded, apply penetrating oil and allow to soak, or carefully use an impact driver. This screw may be damaged during removal and should be replaced if stripped.
   Torque spec

   Rotor Set Screws8 Nm (6 lb-ft)
5. 5

   Remove old rotor
   Pull the rotor straight off the hub. If rotor is stuck due to corrosion, strike the rotor from behind with a dead blow hammer or rubber mallet between the wheel studs. Alternate striking points around the rotor to break it free evenly. Do NOT strike the wheel studs directly. If extremely stuck, apply penetrating oil at the hub/rotor interface and allow to soak.
   ⚠Avoid striking wheel studs or hub bearing directly, as this can cause damage requiring additional repairs.
6. 6

   Clean hub mounting surface
   Use a wire brush to thoroughly clean the hub face where the rotor mounts. Remove all rust, corrosion, and debris to ensure the new rotor sits flush and true. Any high spots or debris will cause rotor runout and brake pulsation. Clean the wheel studs and set screw hole as well.
   ⚠Do not use compressed air to clean brake dust. Use wet methods or HEPA vacuum only.
7. 7

   Install new rotor
   Remove any protective coating from the new rotor using brake cleaner and a clean cloth (coating prevents rust during storage but must be removed). Place the new rotor onto the hub, aligning the set screw hole. Ensure the rotor sits completely flush against the hub face. Install the rotor set screw and tighten to specification.
   Torque spec

   Rotor Set Screws8 Nm (6 lb-ft)
8. 8

   Compress caliper piston
   Before reinstalling the caliper bracket, compress the caliper piston(s) back into the caliper bore using a brake caliper compression tool or large C-clamp. Place an old brake pad against the piston to protect it, and slowly compress until piston is fully retracted. This is necessary to accommodate the thickness of the new rotor and pads. Monitor brake fluid reservoir for overflow.
   ⚠Compress piston slowly to avoid damaging caliper seals or forcing fluid past master cylinder seals.
9. 9

   Reinstall caliper bracket
   Position the caliper bracket over the new rotor and align mounting holes with the steering knuckle. Install both bracket bolts hand-tight first to ensure proper thread engagement. Apply thread locker to bolts if recommended. Torque both bracket bolts to specification using a torque wrench in a criss-cross pattern.
   Torque spec

   Bracket Bolts117 Nm (86 lb-ft)
10. 10

    Reinstall caliper assembly
    Remove the caliper from its support wire. Ensure brake pads are properly seated in the bracket. Clean the caliper slide pins with a clean cloth, then apply a thin layer of silicone brake grease to the pins (do NOT use petroleum-based grease). Lower the caliper over the rotor and pads, aligning the slide pin bolt holes. Install both slide pin bolts hand-tight, then torque to specification.
    Torque spec

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

    Reinstall wheel
    Place the wheel onto the hub and install all lug nuts by hand. Tighten lug nuts in a star pattern until snug using hand tools. Do not fully torque yet. Lower vehicle until tire just touches the ground but vehicle weight is still on jack stands.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)
12. 12

    Final torque and brake bed-in
    With tire on ground but vehicle still slightly supported, torque all lug nuts to specification in a star pattern using a torque wrench. Fully lower vehicle and remove jack stands. Before moving vehicle, pump brake pedal slowly several times until pedal feels firm and normal. Check brake fluid level and top off if needed with DOT 4 LV fluid. The pedal will initially go to the floor due to caliper piston retraction.
    ⚠️Do NOT drive vehicle until brake pedal is pumped to restore proper pedal height and feel. Failure to do so will result in no braking on first pedal application.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification using a calibrated torque wrench.
2. Verify caliper is securely mounted and brake hose has no kinks or tension.
3. Check brake fluid level in master cylinder reservoir and top off to MAX line if needed with Motorcraft DOT 4 LV brake fluid only.
4. Verify wheel lug nuts are torqued in proper star pattern.

Verification

• Pump brake pedal 10-15 times until pedal feels firm and reaches normal height. Pedal should not go to floor.
• Start engine and verify brake warning light is off on instrument cluster.
• Perform a low-speed brake test (5-10 mph) in a safe area to verify proper brake function before driving normally.
• Perform initial bed-in procedure: make 10-15 moderate stops from 30-40 mph with 30 seconds between stops to properly seat pads to new rotor surface. Avoid hard braking for first 200 miles.
• Check for any unusual noises, vibrations, or pulling during braking. Recheck all fasteners after first 50 miles of driving.
• Inspect for any brake fluid leaks around caliper and brake lines after test drive.

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