Ford Explorer 2020-2026 HD Challenge Rear Brake System

Complete Rear Brake System Upgrade for the 2020-2026 Ford Explorer ST 3.0L EcoBoost

The Rotora HDExplorer-355x29 is a purpose-built rear brake system replacement for the 2020-2026 Ford Explorer ST. This is a full system, not a rotor upgrade. Every component needed to replace the factory rear brake assembly is included: ductile iron calipers with stainless steel pistons, 355x29mm directional disc rings in your choice of Slotted or Drilled finish, 2-piece bell hats with HD float drive hardware, carbon steel caliper brackets with hardware, HD graphite-metallic brake pads, DOT-compliant stainless steel braided brake lines, and an Electronic Parking Brake Bypass (EPBB) module that maintains full integration with the Explorer ST's factory electric parking brake. The HD Challenge series was engineered for light-duty and medium-duty SUVs that are used for serious towing, hauling, and off-road work where the factory brake system is not sized for sustained high-load use. The HDExplorer-355x29 is 100% application-specific to the Explorer ST, with full compatibility to the stock master cylinder, ABS, and traction control requiring no ECU reprogramming beyond the EPBB module installation.

Key Features

• Complete rear brake system for 2020-2026 Ford Explorer ST including calipers, rotors, hats, brackets, pads, brake lines, and EPBB module
• 355x29mm directional 2-piece disc rings in Slotted or Drilled finish
• Ductile iron calipers with stainless steel pistons and dust boot seals
• S45C steel bell hats with stainless steel HD float drive hardware
• Carbon steel (S45C) caliper brackets with full hardware
• HD graphite-metallic brake pads with enlarged pad area for higher thermal capacity and longer pad life
• DOT-compliant stainless steel braided brake lines for stiffer pedal feel and zero hose expansion under load
• Electronic Parking Brake Bypass (EPBB) module for full factory EPB compatibility
• Oversize airfoil slotted discs increase brake torque, thermal mass, disc life, and cooling airflow
• 100% compatible with factory master cylinder, ABS, and traction control on 2020-2026 Explorer ST
• Higher-compound pad upgrades (H6, H8, H9) available by request at time of order

Fitment

Specifications

What's Included

• 2x ductile iron rear brake calipers with stainless steel pistons and dust boot seals
• 2x 355x29mm directional disc rings (Slotted or Drilled per variant selected)
• 2x S45C steel bell hats with stainless steel HD float drive hardware
• 2x carbon steel (S45C) caliper brackets with full hardware kit
• 1x set HD graphite-metallic rear brake pads
• DOT-compliant stainless steel braided rear brake lines
• 1x Electronic Parking Brake Bypass (EPBB) module
• Installation hardware and instructions

About Rotora

Rotora is a US-based manufacturer of high-performance brake systems developed for street, track, and severe-duty applications. The HD Challenge series was designed specifically for light-duty and medium-duty SUVs used in demanding towing, hauling, and off-road conditions where factory brakes are not built for sustained high-load cycles. Rotora applies engineering experience gained from supplying brake systems to armored vehicle, security, and military manufacturers. Every HD Challenge system is engineered application-specific to maintain full compatibility with factory master cylinder, ABS, and traction control without vehicle reprogramming.

Frequently Asked Questions

No. The included EPBB module handles the electric parking brake integration on the 2020-2026 Explorer ST. Beyond installing the EPBB module per Rotora's instructions, no dealer visit, scan tool programming, or ECU recalibration is required. The system is plug-and-play with the factory ABS and traction control.

Yes. The HDExplorer-355x29 is engineered to fit the 2020, 2021, 2022, 2023, 2024, 2025, and 2026 Ford Explorer ST. All model years in this range use the same rear brake architecture with the electric parking brake that requires the included EPBB module.

Both variants use the same 355x29mm 2-piece disc, calipers, pads, hardware, and EPBB module. The Slotted disc features directional curved slots that vent gas and continuously clean the pad surface under hard braking. The Drilled disc adds cross-drilled holes for greater heat venting and a more aggressive appearance. For primarily street and towing use, the Slotted disc is generally more durable under repeated severe-load braking. The Drilled disc is better suited to mixed street and track use where maximum heat venting is a priority.

This is a complete rear brake system replacement. The HDExplorer-355x29 includes calipers, 355x29mm disc rings, bell hats, caliper brackets, HD brake pads, stainless steel brake lines, and the EPBB module. Nothing from the factory rear brake assembly is reused. The system is designed to be installed as a complete unit.

Yes. The included EPBB module restores full electric parking brake function after installation on the 2020-2026 Explorer ST. The module must be installed per Rotora's wiring instructions before the parking brake is cycled. Do not attempt to use the electric parking brake before the EPBB module is connected.

The HDExplorer-355x29 is engineered for the Explorer ST only. The ST uses a specific brake caliper and rotor package that differs from other Explorer trims. Confirm with Rotora before ordering if you have a non-ST Explorer, as bracket fitment and caliper clearance are not guaranteed on other trims.

Yes. The HDExplorer-355x29 includes HD graphite-metallic pads as standard. Rotora offers H6 Street Track, H8 Track Race, and H9 Race compound upgrades for applications that require greater thermal capacity. Specify your pad compound preference at time of order through Black Ops Auto Works.

The HD Challenge system is built to order. Lead time is typically 4-6 weeks from order confirmation. The system ships via UPS Ground or FedEx Ground in heavy-duty foam-lined packaging due to the oversize nature of the brake components.

Yes. A proper bed-in procedure is required after installing new calipers, rotors, and pads to seat all components correctly and transfer an even pad deposit layer to the rotor surface. Perform the bed-in on a safe, open surface before any towing or aggressive driving. Follow the Rotora bed-in procedure included in the HDExplorer-355x29 documentation.

Installation Notes

1. Safely lift and support the Explorer ST at the rear axle. Remove both rear wheels.
2. Enter brake service mode through the vehicle menu or a scan tool to retract the electric parking brake piston before removing the factory caliper. Skipping this step can damage the factory EPB actuator.
3. Remove the factory rear caliper and bracket. Photograph brake line routing before disconnecting.
4. Remove the factory rotor from the hub. Clean the hub flange surface of rust and debris before mounting the new disc assembly.
5. Install the Rotora caliper bracket with the supplied hardware. Torque to specification.
6. Install the 355x29mm 2-piece disc ring and bell hat assembly onto the hub. Verify the directional orientation of each rotor per Rotora's left and right markings.
7. Install the Rotora ductile iron caliper onto the bracket. Connect the stainless steel braided brake line and torque all fittings to specification.
8. Install the HD graphite-metallic rear brake pads with all hardware clips fully seated.
9. Wire and install the EPBB module per Rotora's dedicated EPBB installation instructions before reconnecting vehicle power or cycling the electric parking brake switch.
10. Bleed the rear brake circuit completely to remove all air from the new calipers and brake lines. Confirm firm pedal feel before reinstalling wheels.
11. Reinstall wheels and torque lug nuts to specification. Lower the vehicle.
12. Perform Rotora's bed-in procedure on a safe surface before returning the vehicle to service.

WARNING: This product can expose you to chemicals including lead and phthalates, which are known to the State of California to cause cancer and reproductive harm. For more information go to www.P65Warnings.ca.gov.