Here's a general outline of the process:
1. Safety First:
* Engage parking brake: This is crucial to prevent the vehicle from rolling.
* Chock the wheels: Use wheel chocks on the front wheels to further secure the truck.
* Wear safety glasses and gloves: Protect yourself from flying debris and potential cuts.
* Raise the vehicle securely: Use jack stands under the frame, *never* rely solely on a jack.
2. Remove the Wheel:
* Loosen the lug nuts before jacking up the truck.
* Remove the wheel.
3. Remove the Caliper:
* Locate and disconnect the brake line: Carefully disconnect the brake line using a flare nut wrench. Have a rag ready to catch any brake fluid that might spill.
* Remove the caliper mounting bolts: These are usually located on the back of the caliper. Use the appropriate size socket and wrench.
* Support the caliper: The caliper is heavy and contains brake fluid; use a bungee cord or wire to hang it from the suspension so it doesn't strain the brake line.
4. Remove the Rotor:
* Remove the caliper mounting bracket (if applicable): Some F-150s might require removing the caliper bracket before accessing the rotor.
* Remove the rotor: This might require some persuasion. Sometimes they are held on by rust, so using a rubber mallet or a brake rotor puller can help. Be careful not to damage the wheel studs.
5. Install the New Rotor:
* Clean the hub mating surface: Ensure the hub is clean and free from rust and debris.
* Install the new rotor: Slide the new rotor onto the wheel studs.
6. Install the New Brake Pads:
* Inspect the caliper: Check the caliper pistons and seals for wear or damage. If necessary, replace the caliper.
* Compress the caliper piston(s): This is usually done using a C-clamp and a block of wood to avoid damaging the piston. You might need a specialized caliper piston compression tool.
* Install the new brake pads: Insert the new brake pads into the caliper.
* Reinstall the caliper: Make sure the caliper is properly seated and bolt it back on.
7. Reinstall the Wheel and Bleed the Brakes:
* Reconnect the brake line: Tighten the brake line connection securely.
* Reinstall the wheel: Tighten the lug nuts in a star pattern.
* Lower the vehicle: Carefully lower the vehicle using the jack stands.
* Bleed the brakes: This is crucial to remove any air that may have entered the brake lines during the process. This typically involves using a brake bleeder and a helper to pump the brake pedal. Again, consult your repair manual for the correct bleeding procedure.
8. Final Checks:
* Torque lug nuts: Tighten the lug nuts to the manufacturer's specified torque.
* Test the brakes: Test the brakes carefully before driving.
Parts You'll Need:
* New rear brake rotors
* New rear brake pads
* Brake fluid
* Brake line wrench
* Socket wrench set
* Wrenches (various sizes)
* C-clamp (for caliper piston compression)
* Jack and jack stands
* Wheel chocks
* Bungee cord or wire
* Rubber mallet (possibly)
* Brake rotor puller (possibly)
* Brake bleeder kit
Remember, this is a simplified overview. Consult a repair manual specific to your 2003 F-150 for detailed instructions, torque specifications, and safety precautions. If you are not comfortable performing this repair, it's best to take your truck to a qualified mechanic. Improperly installed brakes can lead to serious accidents.
