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Ford Flex Front Brake Pads Replacement Guide
How to change the front disc brake pads on a 1st generation 2009 to 2019 Ford Flex SUV with the part numbers.

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2019 Flex Front Wheel
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Slightly Loosen Lug Nuts
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Raise Front of SUV
This automotive maintenance tutorial was specifically written to assist owners of the first generation (2009, 2010, 2011, 2012, 2013, 2014, 2015, 2016, 2017, 2018 & 2019) Ford Flex crossover SUV in changing the front disc brake pads and lubricating the caliper slider pins.

Owners of other Ford or Lincoln vehicle such as the Explorer, Fiesta, Focus, Fusion, C-Max, Mustang, Taurus, EcoSport, Escape, Edge, Expedition, Transit Connect, F-150, Ranger, MKZ, MKC, Navigator, MKX and Continental may also find these DIY instructions to be helpful.

A few compatible sets of new front brake pads with their part numbers are as follows: Power Stop 16-1508, Bendix CFC1508, Motorcraft BR1508, ACDelco 14D1508CH and Wagner QC1508.

The correct compatible brake pads may vary depending on the model year of your Flex, whether it has the HD (heavy duty) braking system and also if the transmission is AWD (all wheel drive) or FWD (front wheel drive). Please verify the correct part numbers by using the Amazon Part Finder website before buying new pads.

The tools and other items needed to complete this procedure include a lug nut wrench, a floor jack, two jack stands, a 17mm wrench or a 17mm socket with a 3/8" drive ratchet an "F" clamp and a tube of brake caliper grease.



 

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Spin Off Five Lug Nuts
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Five Lug Nuts Removed
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Rotor, Bracket, Caliper
The first few steps are to drive the SUV on to a level surface, shift the transmission into park and turn off the ignition.

Then engage the emergency / parking brake and place wheel chocks on both sides of the rear tires to prevent the vehicle from moving.

Slightly loosen the five lug nuts on the front wheel by turning them in the counterclockwise direction about 1/4 to 1/2 turn.

Carefully raise the front of the SUV with the floor jack and securely support it with at least two jack stands.

Please do not solely rely on the floor jack to support the vehicle.

I prefer to only work on one side of the vehicle at a time to keep three tires on the ground for extra safety.

Spin off the five lug nuts and set them aside in a safe place.

Remove the front wheel to reveal the caliper, bracket, rotor and suspension.

Set the front wheel aside in a safe place. Some people like to place the wheel under the frame rail of the car just in case the jack stands fail.

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Front Brake Caliper
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Loosen Lower Bolt
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Loosen Upper Bolt
The front brake caliper is held in place to the bracket by two bolts located on the back side of the caliper.

The two bolt heads face in towards the engine bay.

Loosen the lower caliper bolt by turning it in the clockwise direction (as seen from the outside of the vehicle) with the 17mm wrench or a 17mm socket and a 3/8" drive ratchet.

If you have trouble loosening the bolt, use a rubber mallet to hit the end of the wrench.

Then loosen the upper caliper bolt by turning it in the clockwise direction (as seen from the outside of the SUV).

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Removing Top Bolt
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Removing Bottom Bolt
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Lower Bolt / Slider Pin
Spin out the two bolts and remove them from the caliper.

The caliper bolts also act as the caliper slider pins.

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Upper Bolt / Slider Pin
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Lift Off Brake Caliper
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Rest Caliper On Rotor
Set the two combination caliper bolts / slider pins on a clean paper towel or rag.

Carefully pull the caliper out of the bracket and off the old pads.

Rest the caliper on the rotor or suspend it from the spring with a bungee cord or a piece of twine.

Try to avoid bending, kinking, twisting or pulling on the rubber brake fluid hose.

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Remove Old Inner Pad
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Remove Old Outer Pad
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Pad Abutment Clip
Pull the old inner and outer brake pads out of the bracket.

If your new set of front brake pads includes a bag of replacement hardware, pull the old metal pad abutment or "anti-rattle" clips out of the top and bottom of the bracket.

Clean off the rotor, bracket and lug studs with brake parts cleaner spray.

Apply some brake parts lubricant grease to the new pad abutment clips where they will come in contact with the bracket or the new brake pads.

Push the new pad abutment clips into the bracket. Make sure they are fully seated.

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Replace Abutment Clips
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Upper Clips
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Attach "F" Clamp
In order for the caliper to fit over the thicker new brake pads, the two pistons need to be compressed or "retracted" back into the caliper.

Attach the "F" clamp to the caliper and use the back of an old brake pad to evenly distribute the pressure across the two pistons.

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Brake Fluid Reservoir
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Twist Off Plastic Cap
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Compress Caliper Pistons
Move to the right rear area of the engine bay.

Twist off the black plastic brake fluid reservoir cap in the counterclockwise direction and set it aside in a safe place.

Removing the reservoir cap will allow the brake fluid to more easily travel back through the lines when you compress the caliper pistons.

Slowly turn the "F" clamp handle in the clockwise direction to compress back the caliper pistons.

Repeatedly check the level in the reservoir to make sure it doesn't overflow.

Be sure to clean up any spilled brake fluid immediately since it can easily damage painted surfaces.

Continue compressing the caliper pistons until they are flush with the rubber dust boots that surround them.

You may need to re-position the "F" clamp to fully compress the second caliper piston.

Try to avoid pinching or otherwise damaging the rubber dust boots that surround the two caliper pistons.



 

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Move Clamp - 2nd Piston
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Replace Reservoir Cap
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Install New Outer Pad
Once the two pistons are fully compressed, detach the clamp and discard the old brake pad.

Replace the reservoir cap as soon as possible.

Brake fluid is hygroscopic (absorbs moisture from the air), so having it be exposed for a long period of time can lead to reduced braking performance, especially if you live in a humid climate.

If you've been feeling pulsations or vibrating in the front end when you step on the brake pedal, the rotors might be warped and should be replaced with new rotors.

To replace the rotors, remove the two 18mm bracket bolts, remove the Torx T35 set screw on the outer face of the rotor and slide it off the wheel hub. If you have trouble removing the old rotor, hit it a few times with a rubber mallet.

The 18mm rotor bolts should be tightened to 111 lb-ft of torque.

Install the new outer brake pad into the bracket.

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Install New Inner Pad
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Push Pads Against Rotor
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Lower Caliper Over Pads
Install the new inner brake pad into the bracket.

Push the two pads together until they are flush against the rotor.

Carefully lower the caliper over the new pads and into the bracket.

If the caliper won't fit over the new pads, you may need to compress the two pistons back a bit further.

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Lubricate Slider Pins
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Replace Lower Bolt / Pin
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Replace Upper Bolt / Pin
Line up the bolt holes in the caliper with their corresponding bolt holes in the bracket.

In order for the caliper to operate smoothly, the two caliper slider pins or "guide bolts" need to be well lubricated.

Apply a thin layer of grease to the smooth parts of the two combination caliper bolts / slide pins.

Do not apply grease to the threads on the bolt.

Spin in the two bolts a few turns by hand in the counterclockwise direction (as seen from the outside of the vehicle) to prevent them from becoming cross threaded.

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Tighten Counterclockwise
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Tighten Lower Bolt
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Use Torque Wrench
Tighten the two bolts with the 17mm wrench or a 17mm socket with a 3/8" drive ratchet to just past hand tight.

If you have a torque wrench, the service manual specification for the caliper bolts is 53 lb-ft of torque.

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Torque To Specification
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Rubber Valve Cap
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Brake Fluid Bleeder Valve
Double check that the two caliper bolts are tight before moving on to the next steps.

If the brake pedal has been feeling soft or spongy, there might be a few air bubbles or some moisture in the brake lines. It would be best to flush out the old brake fluid at this time. I recommend using a bleeder bottle that makes this an easy one person job. Check out my Acura MDX brake fluid bleeding guide where I use a bleeder bottle.

The brake fluid bleeder valve is located just below the upper caliper bolt. It is under a black rubber cover. It can be opened and closed with a 10mm wrench.

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Brake Pads Replaced
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Replace Front Wheel
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Spin On Five Lug Nuts
Carefully replace the front wheel on to the lug studs.

Spin on the five lug nuts a few turns in the clockwise direction to prevent them from becoming cross threaded.

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Slightly Tighten Lug Nuts
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Lower Car From Stands
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Torque To 100 lb-ft
Slightly tighten the five lug nuts in a criss-cross or star pattern with the tire iron.

Carefully lower the vehicle from the jack stands by using the floor jack.

Continue progressively tightening the lug nuts in a criss-cross or star pattern to about 1/4 to 1/3 turn past hand tight.

It would be best to use a torque wrench to properly tighten the lug nuts to 100 lb-ft of torque as specified in the owner's manual.

Sit in the driver's seat and firmly press on the brake pedal a few times to restore the brake line pressure.

Be sure to write down the brake job in your vehicle's service records.

Please check out all of my Ford Flex DIY Repair & Maintenance Guides.
 

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