🔧 Flex - Rear Brake Pads & Rotor Replacement

You’ll remove the rear wheels, take off the rear brake caliper and bracket, replace the pads and rotors, then reassemble and torque everything correctly. This restores braking performance and prevents vibration or grinding caused by worn pads or warped rotors.

Difficulty Level: Intermediate | Estimated Time: 2-4 hours

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⚠️ Safety & Precautions

• ⚠️ Support the Flex with jack stands, never the jack alone.
• ⚠️ Keep the parking brake fully RELEASED while working on the rear brakes.
• ⚠️ Do not press the brake pedal with a caliper removed.
• ⚠️ Brake dust is harmful; use brake cleaner, not compressed air.
• ⚠️ If brake fluid rises near “MAX” when compressing pistons, remove a little with a suction tool.

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🔧 Required Tools

You'll need the following tools for this repair:

• Floor jack (rated 3-ton minimum)
• Jack stands (rated 3-ton minimum)
• Wheel chocks
• 21mm socket
• 3/8" drive ratchet
• 1/2" drive breaker bar
• Torque wrench (20-200 ft-lbs range)
• 13mm socket
• 15mm socket
• 18mm socket
• Flathead screwdriver
• C-clamp brake piston compressor
• Bungee cord
• Wire brush
• Rubber mallet
• Brake parts cleaner
• Nitrile gloves
• Safety glasses

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Rear brake pad set - Qty: 1
• Rear brake rotors - Qty: 2
• Brake caliper hardware kit (clips/shims) - Qty: 1
• High-temperature brake lubricant - Qty: 1
• Brake fluid (DOT 3) - Qty: 1 quart

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📋 Before You Begin

• 🅿️ Park on level ground and release the parking brake.
• 🧱 Chock both front wheels with wheel chocks.
• 🔩 Crack the rear lug nuts loose with a 21mm socket and breaker bar before lifting.
• 🧴 Open the hood and check the brake fluid level; plan for it to rise when compressing caliper pistons.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Lift and secure the rear

• Use a floor jack (rated 3-ton minimum) to lift the rear and place jack stands (rated 3-ton minimum) under the rear support points.
• Remove the rear wheels using a 21mm socket and 3/8" drive ratchet.

Step 2: Remove the rear caliper (pads come off with it)

• Turn the steering wheel is not needed for the rear; position yourself for a clear view of the caliper.
• Remove the two caliper slide pin bolts using a 13mm socket (some setups may use 15mm socket).
• Lift the caliper off the bracket and hang it from the suspension using a bungee cord.
• Never let the caliper hang by the hose.

Step 3: Remove the caliper bracket

• Remove the two caliper bracket bolts using an 18mm socket and a breaker bar.
• Set the bracket aside.

Step 4: Remove the old rotor

• If the rotor is stuck, spray the hub area with brake parts cleaner and knock the rotor hat with a rubber mallet until it breaks loose.
• Clean the wheel hub face with a wire brush so the new rotor sits perfectly flat.
• A clean hub helps prevent brake vibration.

Step 5: Install the new rotor

• Clean the new rotor friction surfaces with brake parts cleaner (this removes packing oil).
• Slide the new rotor onto the hub.
• To hold it in place, thread on 1-2 lug nuts by hand (backwards is fine) and snug them using a 21mm socket.

Step 6: Service the bracket and install new hardware clips

• Remove the old pad clips from the bracket using a flathead screwdriver.
• Install the new clips from the brake caliper hardware kit by hand (press them fully into place).
• Apply a very thin film of high-temperature brake lubricant to the pad “ears” where they slide in the clips.

Step 7: Reinstall the caliper bracket

• Position the bracket over the rotor and start the bolts by hand.
• Tighten using an 18mm socket and finish with a torque wrench.
• Torque to 115 Nm (85 ft-lbs).

Step 8: Compress the caliper piston

• Remove the old inner pad from the caliper and place it against the piston face.
• Use a C-clamp brake piston compressor to slowly push the piston straight back into the caliper.
• Check the brake fluid reservoir while compressing and prevent overflow.
• Go slow to avoid damaging seals.

Step 9: Install the new pads and reinstall the caliper

• Install the new inner and outer pads into the bracket by hand (they should slide smoothly in the clips).
• Apply a small amount of high-temperature brake lubricant to the caliper slide pins if they are dry.
• Set the caliper over the new pads and start the slide pin bolts by hand.
• Tighten using a 13mm socket (some setups may use 15mm socket), then torque with a torque wrench.
• Torque to 35 Nm (26 ft-lbs).

Step 10: Reinstall wheels and torque lug nuts

• Reinstall the wheels and hand-thread lug nuts.
• Lower the Flex to the ground using a floor jack (rated 3-ton minimum).
• Tighten lug nuts in a star pattern with a torque wrench.
• Torque to 135 Nm (100 ft-lbs).

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✅ After Repair

• 🦶 Pump the brake pedal 10-15 times until it feels firm (this seats the pistons against the new pads).
• 🧴 Re-check brake fluid level and top off with DOT 3 if needed.
• 🧪 Test at low speed first; confirm no pulling, grinding, or warning lights.
• 🔥 Bed-in the pads: make 6-8 medium stops from ~40 mph to ~10 mph, allowing short cool-down between stops.

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💰 DIY vs Shop Cost

Shop Cost: $500-$900 (parts + labor)

DIY Cost: $180-$350 (parts only)

You Save: $320-$550 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 2-3 hours.

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🎯 Ready to get started?

HowToo makes it easy: same-day/2-day shipping on every part, plus all the tools and specialty tools you need! Check out the parts and tools sections below to add everything to your cart.

Assumption: Your Flex uses a standard rear caliper piston (push-in) and common Ford rear fasteners; if a bolt size differs, use the matching socket that fits snugly.