Front pads and rotors on a 6G Bronco run 1.5–2.5 hours in the driveway. Rotor nominal thickness is 34mm and the discard spec is 22mm — once you measure under 22mm, replace, don't resurface. Caliper bracket bolts torque to 129 Nm (about 95 ft-lbs).
This is a safety-critical job. If you're new to brake work, read the whole procedure before starting and consider doing one side at a time so the assembled side stays as a reference. The 6G's front brakes are conventional dual-piston floating calipers — same general layout as F-150, straightforward to service, parts widely stocked.
You'll know it's time when the pad indicator squeals at low speed, the pedal feels longer than it used to, or you see less than 3mm of pad material left behind the wheel spokes. Rotor replacement is recommended any time you replace pads if the rotor is at or near minimum thickness, has heat-cracked surfaces, or has a measurable lip on the outside edge. Trail use (especially water crossings followed by hard descents) warps rotors faster than highway driving.
Pick a flat surface, chock the rear wheels, break the lug nuts loose with the wheels on the ground, then jack the front and set stands under the frame rails. Pull both front wheels. The caliper is held by two slider bolts on the back (15mm head, often with a flat to hold the slider pin); remove those and lift the caliper off — don't let it dangle by the hose, support it with a hook or zip-tie to the coil spring. Pads slide out of the bracket. To remove the rotor, the bracket bolts off (two large 21mm bolts at the back of the knuckle, 129 Nm spec). The rotor lifts free — sometimes with a tap from a dead-blow hammer if rust has welded it to the hub.
Wire-brush the hub mating surface clean — rust here is the most common cause of brake judder after a rotor swap. Set the new rotor on, hand-thread one lug nut to hold it. Bolt the bracket back on at 95 ft-lbs (129 Nm). Compress the caliper piston with a C-clamp or piston tool — open the bleeder first so old fluid pushes out into a rag rather than back into the master cylinder. Slide new pads into the bracket, lube the slider pins lightly with caliper grease, and reinstall the caliper. Torque the slider bolts to 23 ft-lbs (31 Nm).
Reinstall the wheels, lug nuts at 150 ft-lbs (204 Nm) in a star pattern. Before driving, pump the brake pedal slowly until it firms up — it will feel scary-soft on the first one or two strokes after a piston compression. Bed the pads in with 8–10 stops from 35 mph down to 5 mph, then a five-minute cool-down at speed without dragging the brakes.
| Part | Vendor | Est. price |
|---|---|---|
| Motorcraft front brake pads (ceramic) | Ford / Amazon | ~$75 |
| Centric Premium front rotors (pair) | RockAuto / Amazon | ~$130 |
| Brake caliper grease packet | Permatex / CRC | ~$6 |
Written and maintained by an AZ wheeler and driveway wrencher. Always cross-reference your factory service manual — modifications affect vehicle safety and warranty. Work at your own risk.