How to Remove a Front Brake Rotor From a 2002 F150 4X4

The Ford F-150 was introduced in 1975 and eventually replaced the F-100. The 2002 Ford F-150 was equipped with a 4.2-liter V-6 as the base engine. Two versions of the 4.6-liter V-8 and two versions of the 5.4-liter V-8 were also available in the 2002 F-150. The rotors on the 2002 F-150 can wear out over a period of time, depending upon the driver's driving style. When removing the rotors for replacement it is recommended that you replace the brake pads as well to ensure congruity in the brake system.

Instructions

1

Loosen the front lug nuts with a tire iron. Raise the front of the F-150 with a jack. Place jack stands beneath both ends of the axle housing, as far apart as possible. Lower the truck onto the jack stands. Remove the lug nuts and then remove the front wheels completely.

2

Remove the caliper mounting bolts with a 3/8-inch drive ratchet, along with a socket or a hex head adapter (Allen head). Pull the caliper free from the brake assembly and hang it from the front coil spring with a metal clothes hanger. Remove the brake pads from the vehicle completely.

3

Remove the caliper bracket bolts with a 1/2-inch drive ratchet and socket. Remove the caliper bracket. Remove the old rotor from the F-150. Set one of the old brake pads across both caliper pistons in the inboard side of the caliper. Wrap a C-clamp around the old brake pad and the rear of the caliper. Tighten the C-clamp slowly to completely compress both caliper pistons.

4

Install the new brake rotor on the F-150 hub. Turn one lug nut onto the stud and against the face of the rotor. Clean the front and rear side of the rotor thoroughly with aerosol brake cleaner to remove the rust prevention oil from the rotor.

5

Install the caliper bracket and tighten the bolts to 148 foot-pounds, with a 1/2-inch drive torque wrench and socket. Install the brake pads onto the caliper bracket. Make sure the brake pad with the metal wear indicator tab is on the inboard side of the rotor. Place a light coat of caliper grease on the rear shim plates of both brake pads.

6

Install the front caliper and tighten the mounting bolts between 21 and 26 foot-pounds, using the torque wrench and a socket.

7

Repeat steps 2 through 6 to complete the rotor and pad replacement on the second side of the F-150. Install the wheels and tighten the lugs snug with a tire iron. Raise the truck off of the jack stands and remove the jack stands from beneath the truck. Lower the truck to the ground. Tighten the lug nuts to 105 foot-pounds of torque with the torque wrench and socket.

8

Proceed to the driver's side of the truck and pump the brake pedal no less than 10 to 15 times. If the brake pedal does not stiffen or create more resistance after you pump it five times, stop pumping the brakes and bleed the brake system.