Safety First:
* Secure the vehicle: Use jack stands to safely lift and support the truck. Never work under a vehicle supported only by a jack.
* Wear safety glasses and gloves.
* Use appropriate wheel chocks on the wheels that remain on the ground.
Tools You'll Need:
* Jack and jack stands
* Lug wrench
* Socket wrench set (metric)
* Torque wrench
* Hammer
* Pry bar (possibly)
* Brake caliper piston compressor tool (C-clamp may work in a pinch, but a proper tool is recommended)
* Wire or zip tie (to hold the caliper out of the way)
* Penetrating oil (like PB Blaster)
Procedure:
1. Remove the wheel: Loosen the lug nuts before jacking up the vehicle. Remove the wheel completely once the truck is safely supported.
2. Remove the caliper:
* Locate the caliper mounting bolts. These are typically on the back of the caliper.
* Spray penetrating oil on the bolts if they are stubborn.
* Unscrew the bolts and carefully remove the caliper. Be cautious; the caliper is heavy and contains brake fluid. You may need to support the caliper with a wire or zip tie to keep it from hanging by the brake line.
3. Compress the caliper piston:
* Use a caliper piston compressor tool to push the piston back into the caliper. This creates space for the rotor to be removed. This is crucial to avoid damaging the brake pads or caliper. *Do not simply push the piston in with a screwdriver or other makeshift tool – you risk damage.* As you compress the piston, you'll likely need to cycle the brake pedal several times to relieve the pressure.
4. Remove the rotor:
* The rotor might be held on by a single center bolt or it might simply slide off. Check your repair manual. In most cases you might need to gently tap it with a hammer to loosen it from its hub. If stubborn, use a pry bar carefully to help dislodge the rotor but avoid scratching the mating surface of the hub.
5. Clean the mating surfaces: Thoroughly clean the hub and the rotor's mating surfaces with a wire brush or brake cleaner. Make sure they are free of rust, dirt, and debris.
Reinstallation:
Reinstallation is the reverse of the removal process. Remember to:
* Lubricate the caliper mounting bolts with anti-seize compound.
* Properly torque all bolts to the specifications in your repair manual.
* Bleed the brakes after reinstallation to remove any air that might have entered the system. (This is very important!)
* Check for proper brake pad thickness.
Important Considerations:
* ABS Sensors: Be mindful of the ABS sensor, typically located near the rear wheel hub. Avoid damaging it during rotor removal and reinstallation.
* Parking Brake: If your vehicle has a drum-in-rotor style parking brake (more common on older F350s), you'll need to address that separately before removing the rotor. This usually involves removing the e-brake shoes and adjusting them. A repair manual will provide specifics.
* Dual Rear Wheels (DRW): DRW trucks have an additional wheel and rotor on each side. The procedure is similar, but you'll have to repeat the steps for both rotors.
This is a complex task; if you are not comfortable working on brakes, it is strongly recommended to take your vehicle to a qualified mechanic. Incorrectly performing brake work can lead to serious safety hazards. Always reference a repair manual specific to your 2003 Ford F350.
