Tools You'll Need:
* Jack and Jack Stands: Safely lift the truck and secure it on jack stands. Never work under a vehicle supported only by a jack.
* Wheel Chocks: Place wheel chocks on the wheels that remain on the ground.
* Lug Wrench: Loosen the lug nuts on the wheel before jacking up the truck.
* Socket Wrench and Sockets: Various sizes depending on your lug nuts and caliper bolts.
* C-Clamp or Brake Caliper Compression Tool: To compress the brake caliper piston.
* Hammer (optional): May be needed to gently tap the rotor loose.
* Wrench or Socket for Rotor retaining bolt(s) (if applicable): Some models have a bolt holding the rotor to the hub.
* Penetrating Oil (PB Blaster, etc.): To help loosen any stubborn bolts.
* Gloves and Safety Glasses: Essential for protection.
Steps:
1. Safety First: Engage the parking brake firmly. Chock the wheels that remain on the ground. Jack up the truck and secure it on jack stands.
2. Remove the Wheel: Remove the lug nuts and take off the wheel.
3. Compress the Brake Caliper Piston: Use the C-clamp or compression tool to push the caliper piston back into the caliper bore. This will give you enough space to remove the rotor. Be careful not to damage the piston or seals. Some pistons will turn as you compress them.
4. Remove the Caliper: You may need to remove the caliper mounting bolts and carefully hang the caliper out of the way using a wire or bungee cord. Do not let the caliper hang by the brake line.
5. Remove the Rotor Retaining Bolt (If Applicable): Some F-150s have a center bolt securing the rotor to the wheel hub. If present, remove this bolt using the appropriate wrench or socket.
6. Remove the Rotor: The rotor should now be free to slide off the wheel hub. If it's stuck, gently tap it around the outer edge with a hammer. Avoid damaging the rotor or hub.
7. Clean the Hub: Once the rotor is off, clean the hub mating surface of any rust or debris.
8. Installation: Installation is the reverse of removal. Be sure to lubricate the rotor mounting surface (hub) with a small amount of anti-seize compound to prevent future rust and corrosion. Torque all bolts to the manufacturer's specifications. You will find these specifications in your owner's manual or a reliable online repair database.
Important Considerations:
* Rust: If the rotor is severely rusted, it might be difficult to remove. Penetrating oil may help loosen it.
* Damaged Rotor: If the rotor is scored, warped, or otherwise damaged, it should be replaced.
* Brake Pad Inspection: While you have the caliper off, inspect the brake pads for wear. Replace them if necessary.
This is a general guide. Specific steps may vary slightly depending on your particular model of 2002 F-150. Always consult a repair manual specific to your vehicle for detailed instructions and torque specifications. If you are unsure about any step, consult a professional mechanic.
