Removing Back Brake Rotors on a 2003 F-150

Since its initial release in 1975, the F-150 has been the best-selling pickup in Fords lineup. The 2003 model was available in three main trim levels: XL, XLT and SVT Lightning. All three trims came standard with four-wheel disc brakes. The XL and XLT had a solid rear rotor, but the SVT Lightning had a ventilated rear rotor to help dissipate heat. Despite this slight difference, replacing the rotor on all three trims of the 2003 F-150 is the same straightforward task.

Instructions

1

Loosen the rear lug nuts with a ratchet and socket and raise the rear of the truck with a floor jack. Position jack stands under the rear of the frame rails and lower the F-150 onto the jack stands. Remove the lug nuts and pull the rear wheels off the truck.

2

Remove the caliper bolts, using a ratchet and socket, and pull the caliper from its bracket. Hang the caliper from a nearby suspension component via a bungee strap.

3

Insert a flat-head screwdriver between the metal clip on the rear of the outer brake pad. Pry upward to release the clip and pivot that side of the pad off the caliper. Pry the other side of the clip up and remove the pad from the caliper.

4

Set a drain pan under the caliper. Position an 8-inch C-clamp on the caliper so its fixed part contacts the rear of the caliper and its screw part contacts the inner brake pad. Loosen the bleeder valve the quarter-inch metal valve on the rear of the caliper with a combination wrench and immediately tighten the C-clamp until the pad stops moving. Immediately tighten the bleeder valve.

5

Grab the inner brake pad and pull it away from the caliper; notice it has metal clips that guide it into the cavity of the calipers piston.

6

Grab the rotor and pull it from the rear hub. If the rotor does not pull off easily, pull the rubber plug from the disc backing plate and turn the parking brake shoe adjuster the star-shaped wheel downward with a flat-head screwdriver to retract them. Press the plug back into the hole.

7

Guide a new rotor onto the hub.

8

Align the metal fingers on the rear of a new inner brake pad with the cavity in the caliper piston. Press the pad toward the piston until it seats flush in the caliper. Align the metal clip on the outer brake pad with the fingers on the outer part of the caliper. Pry upward on one side of the clip with a flat-head screwdriver and press that side of the pad onto the caliper. Pry upward on the other side of the clip and press that side onto the caliper. Press the pad downward until the pads metal clip seats in its grooves in the caliper body.

9

Set the caliper back onto its bracket and hand-thread its bolts. Tighten the caliper bolts to 20 foot-pounds using a torque wrench and socket.

10

Repeat steps 2 through 9 to replace the pads and rotor on the other side of the F-150.

11

Reinstall the rear wheels onto the rear hubs and hand-tighten the lug nuts. Raise the truck off the jack stands with a floor jack and remove the jack stands. Lower the F-150 to the ground and tighten the lug nuts, in a crisscross pattern, to 100 foot-pounds.

12

Press and release the brake pedal until it feels firm. Check the fluid level in the brake master cylinder reservoir. Unscrew the cap from the master cylinder reservoir and add new DOT 3 brake fluid until the level reaches the Max line, if needed.

13

Take the old brake fluid in the drain pan to a used automotive fluid recycler. Some auto parts stores take old fluid for free.