Tools You'll Likely Need:
* Jack and jack stands (essential for safety)
* Wheel chocks
* Wrench or socket set (sizes will depend on your vehicle – check your manual)
* C-clamp or caliper compression tool
* Drain pan
* Brake cleaner
* Rags or shop towels
* Penetrating lubricant (like PB Blaster)
Procedure:
1. Safety First: Park on a level surface, engage the parking brake, and chock the front wheels. Raise the rear of the truck securely using a jack and support it with jack stands. Never work under a vehicle supported only by a jack.
2. Remove the Wheel: Remove the wheel nuts and take off the wheel.
3. Disconnect the Brake Line: Locate the brake line connected to the caliper. You'll likely need a wrench or line wrench to loosen the fitting. Have a container ready to catch any brake fluid that might spill. Some people prefer to use a catch bottle specifically designed for this.
4. Disconnect the Parking Brake Cable: If your F-150 has a drum-in-rotor style rear brake setup (more common on lower trim levels), you'll have a parking brake cable attached to the caliper. Use the appropriate wrench to disconnect this cable. If it's a disc brake system, this step may not apply.
5. Remove the Caliper Bolts: Locate the bolts holding the caliper to the caliper bracket. These are usually on the back of the caliper. Spray penetrating lubricant on the bolts if they're rusty or stuck. Use the appropriate wrench or socket to remove the bolts.
6. Compress the Piston: Before removing the caliper completely, you must compress the brake piston. This allows the caliper to clear the rotor. Use a C-clamp or caliper compression tool to slowly and evenly compress the piston. Be careful not to damage the piston seal. Brake fluid will likely be expelled, so have a drain pan and rags ready.
7. Remove the Caliper: Carefully remove the caliper from the bracket. Support the caliper as you remove it to avoid straining the brake line.
8. Installation (Reverse Order): To reinstall, reverse the above steps. Remember to:
* Bleed the brakes: After reinstalling the caliper and refilling the brake fluid reservoir, you must bleed the brakes to remove any air that might have entered the system. This is crucial for proper braking function. Consult your repair manual for the proper bleeding procedure.
* Torque specifications: Tighten all bolts to the manufacturer's specified torque values.
Important Notes:
* Drum-in-rotor vs. Disc brakes: The 2004 F-150 might have either drum-in-rotor or disc brakes in the rear, affecting some of the steps. Refer to your owner's manual or a repair manual specific to your truck to confirm the type of brake system and the correct procedure.
* Brake fluid is corrosive: Wear gloves and eye protection when working with brake fluid.
* If you're uncomfortable with this repair, take your vehicle to a qualified mechanic. Improper brake repair can be extremely dangerous.
This information is for guidance only. Always consult your vehicle's repair manual for detailed instructions and safety precautions. Remember to prioritize safety throughout the entire process.
