Ford Explorer 2020-2026 HD Challenge Front Brake System

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

The Rotora HDExplorer-355x35 is a full front brake system replacement built specifically for the 2020-2026 Ford Explorer ST. This is not a rotor swap. The kit replaces the entire front brake assembly with ductile iron calipers, 355x35mm directional disc rings in your choice of Slotted or Drilled finish, 2-piece bell hats with HD float drive hardware, carbon steel caliper brackets, HD graphite-metallic brake pads, and DOT-compliant stainless steel braided brake lines. The HD Challenge series is Rotora's purpose-built solution for light-duty and medium-duty SUVs subjected to sustained towing, hauling, and off-road loads where the factory front brake system does not have the thermal capacity to perform consistently. Every component in the HDExplorer-355x35 is engineered application-specific to the Explorer ST, maintaining 100% compatibility with the stock master cylinder, ABS, and traction control with no ECU reprogramming required.

Key Features

• Complete front brake system for 2020-2026 Ford Explorer ST including calipers, rotors, hats, brackets, pads, and brake lines
• 355x35mm directional 2-piece disc rings in Slotted or Drilled finish
• Ductile iron calipers with stainless steel pistons and dust boot seals for maximum stiffness and durability
• 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 service life
• DOT-compliant stainless steel braided brake lines for stiffer pedal feel and zero hose expansion under load
• Oversize airfoil slotted discs increase brake torque, thermal mass, disc life, and cooling airflow under severe braking
• 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 front brake calipers with stainless steel pistons and dust boot seals
• 2x 355x35mm 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 front brake pads
• DOT-compliant stainless steel braided front brake lines
• Installation hardware and instructions

About Rotora

Rotora is a US-based manufacturer of high-performance brake systems for street, track, and severe-duty applications. The HD Challenge series was developed for light-duty and medium-duty SUVs and trucks 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 with no vehicle reprogramming.

Frequently Asked Questions

Yes. The HDExplorer-355x35 is engineered for the 2020, 2021, 2022, 2023, 2024, 2025, and 2026 Ford Explorer ST. All model years in this range share the same front brake architecture on the ST trim.

Both variants use the same 355x35mm 2-piece disc construction, ductile iron calipers, HD pads, and stainless steel brake lines. The Slotted disc features directional curved slots that continuously vent gas and 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 offers greater durability under repeated severe-load braking. The Drilled disc suits mixed street and track use where maximum heat venting is a priority.

This is a complete front brake system replacement. The HDExplorer-355x35 includes ductile iron calipers, 355x35mm disc rings, 2-piece bell hats, caliper brackets, HD graphite-metallic brake pads, and stainless steel braided brake lines. Nothing from the factory front brake assembly is reused. It is not a rotor-only upgrade.

No. The HDExplorer-355x35 is 100% compatible with the factory master cylinder, ABS, and traction control on the 2020-2026 Explorer ST. No dealer visit, scan tool programming, or ECU recalibration is required. Note: unlike the rear system, the front does not involve an electric parking brake and requires no EPBB module.

Yes. The matching rear system for the 2020-2026 Explorer ST is the HDExplorer-355x29, which uses 355x29mm discs and includes the EPBB module for the rear electric parking brake. Both systems can be installed together for a full front-to-rear HD Challenge brake upgrade on the Explorer ST.

The HDExplorer-355x35 is engineered for the Explorer ST only. The ST uses a specific front brake caliper and rotor package that differs from other Explorer trims. Confirm with Rotora before ordering for any non-ST Explorer, as caliper clearance and bracket fitment are not guaranteed across other trim levels.

Yes. The HDExplorer-355x35 includes HD graphite-metallic pads as standard. Rotora offers H6 Street Track, H8 Track Race, and H9 Race compound upgrades for applications requiring greater thermal capacity. Specify your 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. 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 and transfer an even pad deposit layer onto 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-355x35 documentation.

Installation Notes

1. Safely lift and support the Explorer ST at the front axle. Remove both front wheels.
2. Remove the factory front caliper and bracket assembly. Suspend the caliper with a wire hook and do not allow it to hang by the brake hose. Photograph the brake line routing before disconnecting.
3. Remove the factory front rotor from the hub. Clean the hub flange surface of rust and debris before mounting the new disc assembly.
4. Install the Rotora caliper bracket with the supplied hardware. Torque to specification.
5. Install the 355x35mm 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 before tightening.
6. Install the Rotora ductile iron caliper onto the bracket. Connect the stainless steel braided brake line and torque all fittings to specification.
7. Install the HD graphite-metallic front brake pads with all hardware clips fully seated in the caliper bracket.
8. Bleed the front brake circuit completely to purge all air from the new calipers and brake lines. Verify firm pedal feel before reinstalling wheels.
9. Reinstall wheels and torque lug nuts to specification. Lower the vehicle.
10. Perform Rotora's recommended bed-in procedure on a safe, open surface before returning the vehicle to service or towing use.

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.