This procedure covers the replacement of a single rear brake rotor on a 2021-2024 Ford F-150 with 3.5L EcoBoost engine, including caliper removal, rotor replacement, and proper torque specifications.

Warnings

Tools required

Parts

• Rear brake rotor × 1 — Use OEM specification or equivalent quality aftermarket
• Rotor set screw × 1 — M6 x 10mm Torx set screw (often reusable)

Fluids

• Motorcraft DOT 4 LV Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on level, solid surface and engage parking brake firmly
2. Chock the front wheels securely
3. Loosen rear wheel lug nuts 1/4 turn while vehicle is on the ground
4. Raise rear of vehicle with floor jack at manufacturer-specified jacking point
5. Support vehicle with jack stands rated for vehicle weight at proper support points
6. Remove wheel and tire assembly completely
7. Open brake fluid reservoir cap slightly to allow fluid to return when compressing caliper piston
8. Inspect brake fluid level and condition; top off with Motorcraft DOT 4 LV if needed

Procedure

1. 1

   Remove caliper slide pin bolts
   Locate the two caliper slide pin bolts on the rear of the caliper assembly. Using a 13mm socket, remove both slide pin bolts. Keep these bolts as they will be reused. The caliper should now be free to pivot away from the rotor.
   Torque spec

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

   Support and remove brake caliper
   Carefully pivot the brake caliper upward and away from the rotor. Do NOT disconnect the brake hose. Use a wire hanger or bungee cord to securely support the caliper from the suspension or frame. Ensure there is no tension or stress on the brake hose. The caliper must be supported and cannot hang freely.
3. 3

   Inspect brake pads
   With the caliper removed, inspect the brake pads for wear, damage, or contamination. Note the pad thickness and condition. If pads are worn below 3mm or contaminated with fluid/grease, they should be replaced during this service. Remove pads from caliper bracket if necessary for access.
4. 4

   Remove caliper bracket bolts
   Using an 18mm socket, remove the two caliper bracket bolts that secure the bracket to the axle housing. These bolts are torqued to high specification and may require significant force to loosen. Apply penetrating oil if bolts are corroded. Remove the entire caliper bracket assembly.
   Torque spec

   Bracket Bolts117 Nm (86 lb-ft)
5. 5

   Remove rotor set screw and rotor
   Locate the rotor set screw in the face of the rotor (may be centered in the hub area). Using a T30 Torx bit, remove the set screw. If seized, apply penetrating oil and allow to soak. Once removed, pull the rotor straight off the hub. If rotor is stuck, tap gently with a rubber mallet alternating around the rotor face. Do not strike the rotor friction surface directly.
   ⚠Rotor set screws can be easily stripped. Ensure Torx bit is fully seated before applying torque.
   Torque spec

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

   Clean hub mounting surface
   With the rotor removed, thoroughly clean the hub mounting surface using a wire brush. Remove all rust, corrosion, and debris from the hub face and pilot bore. Any irregularities can cause rotor runout and brake pulsation. The surface should be clean and smooth to bare metal.
7. 7

   Prepare and install new rotor
   Clean the new rotor with brake parts cleaner to remove any protective coating or shipping oils. Wipe both rotor surfaces thoroughly and allow to dry. Slide the new rotor onto the hub, aligning the holes. The rotor should sit flush against the hub face with no wobble or gaps.
8. 8

   Install rotor set screw
   Install the rotor set screw and tighten to specification using the T30 Torx bit and torque wrench. This screw retains the rotor during service but is not critical to brake function. Do not overtighten as it can strip easily.
   Torque spec

   Rotor Set Screws8 Nm (6 lb-ft)
9. 9

   Reinstall caliper bracket
   Position the caliper bracket over the rotor and align the mounting holes with the axle housing. Install both caliper bracket bolts and hand-tighten. Using an 18mm socket and torque wrench, tighten both bracket bolts to specification in a crisscross pattern. Ensure bracket is seated properly before final torquing.
   Torque spec

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

    Compress brake caliper piston
    Before reinstalling the caliper, the piston must be compressed to accommodate the new rotor thickness. Using a brake caliper piston tool or large C-clamp, slowly compress the piston fully into the caliper bore. Watch the brake fluid reservoir and remove fluid if it approaches the MAX line to prevent overflow. Compress slowly and evenly.
    ⚠Do not allow brake fluid to overflow from reservoir. Clean any spilled fluid immediately as it damages paint.
11. 11

    Reinstall brake pads if removed
    If brake pads were removed from the caliper bracket, reinstall them now. Ensure anti-rattle clips and shims are properly positioned. Pads should slide freely in the bracket channels but not be loose. Apply a thin coat of silicone brake grease to pad ears and backing plates where they contact the bracket (not on friction surfaces).
12. 12

    Reinstall brake caliper
    Remove the caliper from its support. Apply silicone brake grease to the slide pin bolts. Position the caliper over the rotor and bracket, aligning the slide pin bolt holes. Install both slide pin bolts and hand-tighten. Using a 13mm socket and torque wrench, tighten both slide pin bolts to specification. Verify caliper moves freely on the slide pins.
    Torque spec

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)
13. 13

    Reinstall wheel and tire
    Position the wheel onto the hub and hand-thread all lug nuts. Using a 19mm or 3/4 inch socket, tighten lug nuts in a star pattern to draw the wheel evenly onto the hub. Lower the vehicle until the tire just contacts the ground but still supports vehicle weight on jack stands. Using a torque wrench, torque all lug nuts to specification in a star pattern.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)
14. 14

    Lower vehicle and final torque
    Raise vehicle slightly to remove jack stands. Carefully lower the vehicle completely to the ground. With full vehicle weight on the wheel, perform a final torque check on all lug nuts in a star pattern to specification. Replace the brake fluid reservoir cap securely.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Ensure all tools and parts are removed from under vehicle and wheel well area
2. Remove wheel chocks from front wheels
3. Double-check that all fasteners have been installed and properly torqued
4. Verify brake fluid level is between MIN and MAX marks in reservoir

Verification

• CRITICAL: Before driving, pump the brake pedal several times until it feels firm. The pedal should not go to the floor. If pedal feels soft or goes to floor, do not drive the vehicle.
• Start engine and pump brakes again. Check for warning lights on instrument cluster.
• Perform a low-speed brake test in a safe area (5-10 mph) to verify proper brake function before normal driving.
• Perform 20-30 moderate brake applications from 30-40 mph to properly bed in the new rotor and transfer pad material. Avoid hard braking during initial 200 miles.
• Listen for any unusual noises such as grinding, squealing, or rubbing during brake application and wheel rotation.
• Check for brake fluid leaks around caliper and brake lines after test drive.
• Verify wheel lug nut torque after first 50-100 miles of driving.
• If any vibration, pulsation, or abnormal brake behavior occurs, inspect installation immediately and verify all torque specifications were met.

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