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How to swap 2010+ front brakes on a 2009 (and possibly 2004-2008 4WD)

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How to swap 2010+ front brakes on a 2009 (and possibly 2004-2008 4WD)

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  #1  
Old 07-01-2018, 10:40 PM
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How to swap 2010+ front brakes on a 2009 (and possibly 2004-2008 4WD)

Hi all. Been a while since I've posted anything. I'm just about done upgrading the front brakes on my 2009 to the larger rotors, calipers, and pads used on the 2010+ models. This is something I've been thinking about doing for a few years and after much research and a little luck, it's incredibly simple!

List of 2010 F150 front brake parts needed to swap on a 2009:
  • Calipers
  • Caliper bolts
  • Caliper brackets
  • Pads
  • Caliper bracket bolts
  • Rotors

This is basically a direct swap. The only modification needed is to enlarge the caliper bracket mounting holes on the steering knuckles with a 5/8" drill bit.. The caliper bracket bolts on the 2009 are M14x2.0, but the 2010 caliper bracket bolts are M16x1.5 - though the location of the holes are in the exact same place on the steering knuckles.

I neglected to take any pics during the process, but the new brakes are significantly beefier. The only thing I didn't change is the backing plate for the brake rotor – which isn't going to bother me. I left the original shields in place.




​​​​​​I hit a small snag with the caliper bracket bolts. The aftermarket ones I received (Carlson H814) were 45mm in length, which was 5mm too long. I'm not sure if the 2010 knuckles were thicker at the caliper bracket mounts or if the bolts listed were just wrong. they were uncomfortably close to the rotors when installed, so I shortened them with a cut-off wheel and beveled the end with my bench grinder. If you have the same issue and don't want to shorten the bolts, you could just use thick washers instead.​ The Dorman bolts look like they may be the correct length for this though. I'm not sure how long the OE bolts are. If you're just going to use generic bolts, the size you'd need is M16x1.5x40 and it should have a flanged head and be grade 10.9. The torque spec is 250 Nm (184 lb-ft).





I know this is a pretty half-assed "how-to", but it's very simple. I'm pretty sure this swap would be the same for the 2004-2008 guys (4WD only since the 2WD rotor setup is different), but I didn't do a deep dive into those years.

In short, if you have a 2009 F150 and are due for front pads and rotors, you can upgrade your brakes easily just by adding a pair of calipers, caliper bolts, caliper bracket bolts, and a 5/8 drill bit to the job.

FYI, I swapped in the larger 2010-2013 master cylinder last year which improved the pedal feel tremendously. I did that last year, but never posted it. That one I have pics for and will post more about that process in another thread soon...
 

Last edited by EsJayEs; 07-04-2018 at 01:27 PM.
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  #2  
Old 07-02-2018, 07:59 AM
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Very nice!
 
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Old 07-04-2018, 11:51 AM
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Thanks ManualF150!

Just following-up. The difference in performance is significant. The brakes bite quite hard, yet are still very controllable. hard to say how the setup would feel with the 2009 master cylinder since I had swapped. that out already, but there would be more pedal travel with the 2004-2009 style master cylinder as it has a smaller bore.
 

Last edited by EsJayEs; 07-04-2018 at 01:24 PM.
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  #4  
Old 07-11-2018, 02:02 PM
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One more follow-up. After a little more digging, it appears this brake upgrade as originally stated only applies to the 2009 F150. The 2004-2008 models may still be possible if you also swapped the steering knuckles and hub assemblies from a 2010. This is due to the spacing between the caliper bracket bolts being more narrow on the 2004-2008 models. But I can't say for sure if the 2010 knuckles would fit properly on a 2004-2008.

Then again, with a welder and some solid fabrication skills, anything is possible. I hope this information helps anybody reading this post.
 
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