Tools you'll need:
* Jack and jack stands: Safety first! Never work under a vehicle supported only by a jack.
* Lug wrench: To remove the wheels.
* Wheel chocks: For added safety.
* Sockets and wrenches: Appropriate sizes for your lug nuts and caliper bolts. You'll likely need a socket for the caliper bracket bolts and possibly a wrench for the parking brake cable.
* C-clamp (optional but recommended): To compress the caliper piston.
* Penetrating oil (like PB Blaster): To help loosen rusted bolts.
* Clean rags or shop towels: To keep things clean.
* Torque wrench: To tighten everything back up to the manufacturer's specifications.
Steps:
1. Safety First: Park your F-150 on a level surface, engage the parking brake, and chock the front wheels. Raise the rear of the truck securely using the jack and place it on jack stands.
2. Remove the Wheel: Remove the lug nuts and take off the wheel.
3. Expose the Rotor: You should now see the rotor, brake caliper, and parking brake mechanism.
4. Disconnect the Parking Brake Cable: Locate the parking brake cable connected to the caliper assembly. You'll likely need a wrench to loosen the cable's retaining clip or nut. Carefully disconnect the cable and secure it out of the way to avoid damage.
5. Remove the Caliper: Remove the caliper mounting bolts. These are usually two bolts holding the caliper to the bracket. Once the bolts are removed, carefully lift the caliper away from the rotor. Do not let the caliper hang by the brake hose. You can use a bungee cord or wire to secure the caliper to something nearby, preventing strain on the brake line.
6. Compress the Caliper Piston: Use a C-clamp (or a specialized caliper piston compressor tool) to compress the caliper piston. This will create space to remove the rotor. Turn the piston slowly and evenly to avoid damage to the seals. Be aware that brake fluid will be pushed back into the brake line, so check your brake fluid reservoir before you start and if it's low consider topping it off with the correct type of DOT 3 or DOT 4 brake fluid (check your owner's manual).
7. Remove the Rotor: Once the caliper piston is compressed, the rotor should slide off the wheel studs. It might be slightly tight due to rust, so you may need to gently tap it with a rubber mallet or a block of wood to break it loose.
8. Inspect and Replace: Thoroughly inspect the rotor for wear, scoring, or damage. If it's worn, warped, or cracked, replace it with a new one.
9. Reassembly: Reassembly is the reverse of the removal process. Remember to:
* Install the new rotor.
* Attach the caliper to the bracket.
* Reconnect the parking brake cable.
* Bleed the brakes (this is very important and ensures proper brake function after removing and reattaching the calipers). You’ll need a helper for this step.
* Tighten all bolts to the manufacturer's torque specifications (consult your repair manual for the proper torque values).
* Replace the wheel and lug nuts.
* Lower the vehicle.
* Test your brakes carefully and thoroughly before driving.
Important Considerations:
* Brake Fluid: Always check and top off your brake fluid as needed.
* Torque Specifications: Use a torque wrench and consult your repair manual for the correct torque specifications for all fasteners. Over-tightening can damage threads, while under-tightening can lead to loosening and potential failure.
* Bleeder Valves: It's crucial to bleed the brakes after working on the calipers to remove any air that may have entered the system. If you are not comfortable doing this, have a professional mechanic do it for you.
* Repair Manual: Consult a repair manual specific to your 2004 Ford F-150 for detailed instructions and torque specifications.
If you're not comfortable performing this repair yourself, take your truck to a qualified mechanic. Working on brakes is crucial for safety, and improper repair can have serious consequences.
