Tools You'll Need:
* Wheel Chocks: Essential for safety.
* Jack and Jack Stands: Securely lift the vehicle. Never work under a vehicle supported only by a jack.
* Lug Wrench: To remove the wheels.
* Socket Wrench and Sockets: You'll need the correct sizes for your lug nuts and caliper bolts.
* C-clamp or Rotor Removal Tool: This helps compress the caliper piston to create space for the rotor. A C-clamp is often sufficient, but a dedicated rotor removal tool is easier.
* Hammer (optional): May be needed to gently tap the rotor loose if it's stuck.
* Penetrating Oil (like PB Blaster): Highly recommended to spray on caliper bolts before attempting removal. This helps prevent stripping.
* Wrench or Socket for Caliper Bolt(s): Size will vary depending on your vehicle.
* Gloves and Safety Glasses: Protect yourself.
Procedure:
1. Safety First: Engage the parking brake firmly, chock the rear wheels, and lift the vehicle using the jack and secure it on jack stands. Remove the wheel.
2. Caliper Removal:
* Locate the caliper bolts: These are usually on the back of the caliper.
* Apply penetrating oil: Spray liberally onto the caliper bolts. Let it sit for a few minutes to penetrate.
* Remove the caliper bolts: Use the appropriate wrench or socket to carefully unscrew them. They may be quite tight.
* Support the caliper: Once the bolts are out, carefully support the caliper. You can hang it from the suspension using a wire or bungee cord to keep it out of the way. Do not let the brake line hang freely.
3. Compressing the Caliper Piston: Use the C-clamp or rotor removal tool to compress the caliper piston. This will give you enough clearance to remove the rotor. You may need to pump the brake pedal a few times after reinstalling the caliper to get a good pedal feel.
4. Rotor Removal:
* Inspect the rotor: Note which side was facing outwards.
* Remove the rotor: The rotor should now slide off the hub. If it's stuck, gently tap it with a hammer, working your way around the circumference. Avoid damaging the hub.
5. Installation (Reverse Order): Once the new rotor is in place, follow the above steps in reverse order. Be sure to tighten all bolts to the manufacturer's specified torque. Refer to your repair manual for these torque specifications. This is crucial for safe braking.
6. Brake Fluid Check: After reinstalling the caliper, check your brake fluid level. You might need to add some if the piston was compressed significantly.
Important Notes:
* Brake System: Working on the braking system requires caution. If you're not comfortable performing this repair, take your vehicle to a qualified mechanic. A mistake could have serious consequences.
* Repair Manual: Consult a repair manual specific to your 1992 Ford Aerostar. It will provide precise instructions, torque specifications, and diagrams.
* Rotor Replacement: Consider replacing both rotors on the same axle at the same time for balanced braking.
* Brake Pads: While you have the caliper off, inspect your brake pads. Replace them if they are worn.
This is a general guide. Always prioritize safety and consult your vehicle's repair manual for specific instructions and torque specifications.
