Tools you'll likely need:
* Jack and jack stands: Safely lift the truck and support it. Never work under a vehicle supported only by a jack.
* Wheel chocks: Secure the wheels that remain on the ground.
* Lug wrench: To remove the wheel.
* Sockets and wrench set: Various sizes will be needed. You'll need a socket that fits the caliper mounting bolts, and possibly one for the parking brake cable adjuster (if applicable).
* C-clamp or caliper compression tool: To compress the caliper piston.
* Hammer (optional): May be needed to gently tap things loose.
* Penetrating oil (PB Blaster or similar): To help loosen rusted or stuck bolts.
* Clean rags or shop towels: To keep things clean.
* Safety glasses and gloves: Protect yourself.
Procedure:
1. Safety First: Engage the parking brake, chock the wheels, and safely lift the truck using a jack and jack stands. Place the stands on a solid, level surface.
2. Remove the Wheel: Remove the lug nuts and take off the wheel.
3. Expose the Rotor: You should now see the brake caliper, parking brake cable (if applicable), and the rotor.
4. Compress the Caliper Piston: Using a C-clamp or caliper compression tool, slowly compress the caliper piston. This will give you the clearance needed to remove the caliper. Be careful not to damage the piston seal. Some pistons have a bleed screw you can open slightly to help with this process, making it easier and less likely to damage the seal.
5. Remove the Caliper: Once the piston is sufficiently compressed, remove the caliper mounting bolts and carefully remove the caliper. You may need to support the caliper with a wire or bungee cord to keep it out of the way.
6. Disconnect the Parking Brake Cable (if applicable): If your F-150 has a separate parking brake cable attached to the caliper, you'll need to disconnect it. This usually involves a simple clip or adjuster.
7. Remove the Rotor: The rotor should now be free. Some rotors are held on by only the caliper, while others might have a small retaining clip or bolt. Gently tap the rotor with a hammer and punch (or the handle of a screwdriver) to remove it from the hub. Start tapping at different locations around the rotor to encourage even loosening. Be careful not to scratch the surface of the hub itself.
8. Install the New Rotor (if applicable): Clean the hub thoroughly before installing a new rotor. The new rotor will simply slide onto the hub studs, ensuring it's seated properly.
9. Reassemble: Reinstall the rotor, then the caliper, parking brake cable (if applicable), and tighten all bolts to the manufacturer's specified torque.
10. Bleed the Brakes (Important): After reinstalling the caliper, it's crucial to bleed the brakes to remove any air that may have entered the system during the process. Refer to your owner's manual for bleeding instructions.
11. Reinstall the Wheel: Put the wheel back on and tighten the lug nuts. Lower the vehicle and check the tightness of the lug nuts again.
Important Considerations:
* Rust: If bolts are rusted or seized, apply penetrating oil and let it sit for a while before attempting to remove them.
* Torque Specifications: Always use a torque wrench to tighten bolts to the manufacturer's recommended torque. Over-tightening can damage components.
* Professional Assistance: If you're uncomfortable performing this repair yourself, it's best to take your vehicle to a qualified mechanic. Brake work is critical for safety.
This is a detailed process, and variations may occur depending on your vehicle's specific condition and year. Always consult your owner's manual or a reliable repair manual for specific instructions and torque specifications for your 2003 Ford F-150. Remember, safety should always be your top priority.
