Brake Rotors - Rear Pair

This procedure replaces the rear brake rotors 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 rotors × 2 — Use OEM Ford specification or equivalent
• Rotor set screws (if damaged) × 2 — Use OEM specification

Fluids

• Motorcraft DOT 4 LV Brake Fluid — 0.25 qt

Preparation

1. Park vehicle on level, solid surface and engage parking brake firmly
2. Place wheel chocks in front of both front wheels to prevent rolling
3. If brake fluid reservoir is at MAX line, remove small amount with turkey baster to prevent overflow when compressing caliper pistons
4. Loosen rear wheel lug nuts 1/4 turn while vehicle is on ground (do not remove)
5. Lift rear of vehicle with floor jack at designated rear jacking point and secure with jack stands under frame rails
6. Remove rear wheels completely and set aside

Procedure

1. 1

   Inspect brake system
   Visually inspect the brake caliper, brake hose, and surrounding components for damage, leaks, or excessive wear. Check brake pad thickness - if pads are worn below 3mm, they should be replaced during this service. Note condition of caliper slide pins and boots.
2. 2

   Remove caliper bolts
   Locate the two caliper bolts on the rear of the caliper assembly. Using an 18mm socket, remove both caliper bolts completely. These bolts secure the caliper to the caliper bracket. Keep bolts organized for reinstallation.
   ⚠Support the caliper before removing the second bolt to prevent it from falling and damaging the brake hose.
   Torque spec

   Caliper Bolts102 Nm (75 lb-ft)
3. 3

   Support and secure caliper
   Carefully lift the caliper off the rotor and caliper bracket. Do not allow it to hang by the brake hose. Use wire, a bungee cord, or a hook to suspend the caliper from the suspension or frame. Ensure no tension is placed on the brake hose.
   ⚠️Allowing the caliper to hang by the brake hose can cause internal hose damage leading to brake failure.
4. 4

   Remove caliper bracket
   Locate the two caliper bracket bolts that secure the bracket to the axle housing. These are typically 18mm or 19mm and require significant torque. Using a breaker bar if necessary, remove both caliper bracket bolts and remove the bracket assembly completely. The brake pads will come off with the bracket or may remain on the rotor.
   Torque spec

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

   Remove rotor set screw and rotor
   If present, remove the rotor set screw from the face of the rotor using a T30 Torx bit or Phillips screwdriver. These screws are often corroded and may require penetrating oil or careful drilling if stripped. Once the set screw is removed, pull the rotor off the hub. If the rotor is stuck due to corrosion, tap the rear face with a rubber mallet or use rotor mounting holes with bolts to push it off.
   ⚠Set screws may be severely corroded. Apply penetrating oil and allow time to soak. Do not use excessive force that could damage hub threads.
   Torque spec

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

   Clean hub surface
   Using a wire brush, thoroughly clean the hub face and outer surface where the rotor seats. Remove all rust, corrosion, and debris. The hub face must be clean and flat to ensure proper rotor seating and prevent thickness variation. Spray with brake cleaner and wipe dry with a clean cloth.
   ⚠Do not use compressed air to clean brake dust. Use brake cleaner spray and allow runoff to drip away.
7. 7

   Prepare and install new rotor
   Remove new rotor from packaging. New rotors have a protective oil coating - clean thoroughly with brake cleaner on both sides and the hat section. Allow to dry completely. Apply a thin coat of anti-seize compound to the hub face (not the rotor friction surfaces). Slide the new rotor onto the hub, ensuring it seats flush against the hub face.
   ⚠Any oil, grease, or anti-seize on the rotor friction surfaces will contaminate brake pads and severely reduce braking effectiveness. Keep friction surfaces completely clean.
8. 8

   Install rotor set screw
   If using a rotor set screw, thread it into the hub through the rotor face. Torque to specification. The set screw only holds the rotor during assembly - wheel torque provides final clamping force. If the original screw was damaged, use a new one or leave it out (not structurally required).
   Torque spec

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

   Compress caliper piston
   Before reinstalling the caliper bracket, compress the caliper piston(s) fully into the caliper bore using a C-clamp or brake caliper piston tool. Place the clamp against the piston and the back of the caliper body. Compress slowly and evenly. This creates clearance for the caliper to fit over the new rotor and pads. Monitor brake fluid reservoir - level will rise as piston is compressed.
   ⚠If brake fluid reservoir overflows during piston compression, remove excess fluid immediately to prevent paint damage.
10. 10

    Reinstall caliper bracket
    Position the caliper bracket over the new rotor and align mounting holes with the axle housing. Install both caliper bracket bolts and hand-tighten. Using a torque wrench, torque both bracket bolts to specification in a cross pattern.
    Torque spec

    Bracket Bolts117 Nm (86 lb-ft)
11. 11

    Install brake pads
    If brake pads were removed, install them into the caliper bracket. Ensure anti-rattle clips are properly seated and pads move freely in the bracket. If installing new pads, ensure all hardware and shims are correctly positioned. Apply a thin coat of brake lubricant to pad slide points (not friction surfaces).
12. 12

    Reinstall caliper
    Remove the caliper from its suspended position. Position the caliper over the brake pads and rotor, aligning the caliper bolt holes with the bracket. Install both caliper bolts and hand-tighten. Using a torque wrench, torque both caliper bolts to specification.
    ℹ️Caliper bolts may require thread locker per manufacturer specification. Verify with service manual.
    Torque spec

    Caliper Bolts102 Nm (75 lb-ft)
13. 13

    Repeat for opposite side
    Repeat steps 1 through 12 for the opposite rear wheel. Ensure both sides are completed with equal care and proper torque specifications.
14. 14

    Reinstall wheels
    Clean wheel mounting surface on rotor hat with wire brush. Position wheel onto hub and hand-thread all lug nuts. Tighten lug nuts in a star pattern by hand until wheel is seated against hub. Do not final torque yet.
    ℹ️Final lug nut torque must be performed with vehicle on ground for accurate seating.
15. 15

    Lower vehicle and torque wheels
    Raise vehicle slightly with floor jack and remove jack stands. Lower vehicle completely to ground. Using a torque wrench, torque all lug nuts to specification in a star pattern. Double-check each lug nut to ensure proper torque.
    Torque spec

    Wheel Lug Nuts140 Nm (103 lb-ft)

Reassembly

1. Verify all caliper bolts, bracket bolts, and lug nuts are torqued to specification
2. Check brake fluid level in reservoir and top off with Motorcraft DOT 4 LV brake fluid if needed to bring level to MAX line
3. Do not mix brake fluid types or brands - use only DOT 4 LV specification

Verification

• With vehicle still parked and parking brake off, pump brake pedal 10-15 times until pedal feels firm and consistent. Pedal should not sink to floor.
• Check brake fluid reservoir level - should be at MAX line. Add fluid if necessary.
• Start engine and pump brakes again. Pedal should remain firm. If pedal sinks or feels soft, bleed brake system.
• Inspect all work areas for tools, parts, or hardware left behind. Verify no brake hoses are kinked or stretched.
• Perform a careful test drive in a safe area at low speed (under 15 mph). Apply brakes gently multiple times to seat pads against rotors. Verify straight-line braking with no pulling to either side.
• After initial break-in stops, perform several moderate stops from 30-40 mph to verify proper brake function before returning to normal driving.
• Re-torque wheel lug nuts after 50-100 miles of driving to ensure they remain properly seated.
• Avoid heavy braking for first 200 miles to allow proper pad and rotor break-in and bedding.

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