Tools You'll Need:
* Jack and jack stands (Safety First: Never work under a vehicle supported only by a jack)
* Lug wrench
* Wheel chocks
* Socket wrench set (metric)
* Torque wrench
* Hammer (possibly)
* Penetrating oil (like PB Blaster)
* C-clamp (optional, for forcing the rotor off the hub)
* Wire brush (to clean the hub)
Procedure:
1. Safety First: Engage the parking brake, chock the wheels, and ensure the truck is on a level surface. Raise the truck using the jack and securely place it on jack stands. Remove the wheel.
2. Caliper Removal:
* Disconnect the brake line: Locate the brake line connected to the caliper. You'll likely need a wrench or brake line wrench to loosen the fitting. Have a container ready to catch any brake fluid that may spill. If you have a flexible line, you can carefully loosen the bracket holding it in place to move it out of the way. Otherwise, you'll need to support the weight of the caliper to keep the brake line from being stressed.
* Remove the caliper mounting bolts: These are typically located at the back of the caliper. Use a socket wrench to remove them. Once the bolts are removed, carefully support the caliper to avoid damaging the brake line or stressing it. You may need to use a bungee cord or wire to hang the caliper from a nearby part of the suspension.
3. Rotor Removal: With the caliper removed, the rotor is generally free to slide off. However, there may be some resistance.
* Rust and corrosion: If the rotor is stuck, apply penetrating oil to the hub's mating surface with the rotor. Let it soak for a while (15-30 minutes).
* Tap the rotor: Gently tap the rotor around its circumference with a hammer. This can help break the corrosion bond.
* C-clamp (If necessary): If tapping doesn't work, carefully use a C-clamp to gently force the rotor off the hub. Be careful not to damage the hub or rotor.
4. Clean the Hub: Once the rotor is removed, use a wire brush to clean any rust or debris from the hub mating surface. This will ensure a good fit for the new rotor.
5. Installation: The installation process is the reverse of the removal process. Make sure to lubricate the hub's mating surface before installing the new rotor. Always torque all bolts to the manufacturer's specifications.
Important Considerations:
* Brake fluid: Be careful when working with brake fluid. It's corrosive and can damage paint. Wear gloves and eye protection.
* Torque specifications: Follow the torque specifications in your repair manual for all bolts. Using incorrect torque can lead to premature wear or failure.
* Brake pads: Inspect your brake pads while the caliper is off. If they are worn, replace them.
* Professional help: If you're not comfortable performing this task yourself, take your truck to a qualified mechanic. Brake systems are critical for safety.
This is a general guide. Refer to a repair manual specific to your 1995 Dodge Ram 3500 4x4 for detailed instructions and torque specifications. Failure to follow correct procedures can lead to serious injury or vehicle damage.
