How to Fix the Disc Brake Caliper in a Ford F-150

As system pressure is felt in the disc brake caliper, the caliper piston is forced out of the caliper bore, causing the caliper housing to be pulled toward the rotor. As the piston moves in its bore, the square cut seal around it flexes in its groove in the housing. When the brake pedal is released, the seal straightens and pulls the piston back into the bore slightly to prevent brake pad drag. Repairing the caliper when the seal is damaged or the piston sticks in the bore can extend the life of the brake pads and prevent brake system failure.

Instructions

1

Loosen the front lug nuts using a lug wrench. Apply the parking brake on your F-150 and place wheel chocks behind the rear wheels. Lift the front of the truck using a floor jack placed under the front cross member. Position jack stands under the lower control arms and lower the truck onto the stands. Remove the front wheels.

2

Place a drain pan on the ground, under the left front caliper, and remove the 13 mm banjo bolt that attaches the rubber brake hose to the caliper with a 13 mm socket and ratchet. Remove the two 13 mm caliper bolts that attach the caliper to the caliper support bracket using a 13 mm socket and ratchet. Lift the caliper off the caliper bracket and place it on a work bench.

3

Place a small block of wood in the caliper between the caliper housing and the pistons. Make sure your fingers are clear of the caliper piston. Turn the caliper over and apply compressed air into the bolt hole for the brake hose until the caliper pistons pop out of the housing. Pry the dust boots and internal seals out of the caliper housing with a small screw driver.

4

Clean the caliper housing and the caliper pistons thoroughly with soapy water and a scrub brush. Dry the caliper parts with compressed air.

5

Insert the new caliper seals and dust boots into the caliper housing. Coat the seals, dust boots, inside of the caliper bores and the caliper pistons with a liberal coat of fresh brake fluid.

6

Place the caliper pistons against the dust boots and use a block of wood to hold them in place. Slowly apply compressed air to the brake hose hole to expand the dust boots around the pistons. Slide the caliper pistons into the housing. It may be necessary to push the pistons in with a c-clamp but in most cases they can be pushed in by hand.

7

Install the caliper onto the caliper support bracket and tighten the 13 mm bolts to 25 ft-lbs using a torque wrench. Reinstall the brake hose onto the caliper using the new copper washers supplied in the caliper kit. Tighten the brake hose banjo bolt to 25 ft-lbs using a torque wrench. Repeat the steps for the remaining side of the truck. Bleed the brake system according to the bleeding sequence found in the service manual for the year model F-150 you have.