1. Preparation:
* Safety First: Chock the rear wheels securely. Engage the parking brake. Use jack stands to support the vehicle properly after lifting it with a jack. Never work under a car supported only by a jack.
* Gather Tools: You'll need a lug wrench, jack, jack stands, wheel chocks, a large flat-head screwdriver (or a rotor removal tool), a hammer (rubber mallet is preferred), penetrating oil (like PB Blaster), and possibly a C-clamp.
2. Remove the Wheel:
* Loosen the lug nuts slightly before jacking up the car.
* Jack up the car and securely place it on jack stands.
* Remove the wheel.
3. Remove the Caliper:
* Compress the caliper piston: You'll need a C-clamp or a caliper piston compression tool. This pushes the piston back into the caliper to create space for the rotor. Important: Make sure you are compressing the piston correctly, which might mean opening the brake bleeder valve slightly as you compress to avoid damage. Some calipers require turning the piston. Consult a repair manual for your specific caliper.
* Remove the caliper mounting bolts: These bolts usually are 12mm or 14mm. After removing them, carefully hang the caliper out of the way using a bit of wire or a bungee cord. Avoid letting the brake line hang.
4. Remove the Rotor:
* Penetrating Oil: Apply penetrating oil generously to the mating surface between the rotor and the hub. Let it soak for at least 15-20 minutes. This will help loosen any rust or corrosion.
* Tap the Rotor: Use the flat-head screwdriver or rotor removal tool between the rotor and the hub. Gently tap the screwdriver with a hammer to break the rust and corrosion bond. If it's really stuck, use a rubber mallet instead of a metal hammer to avoid damaging the hub. Work your way around the rotor applying consistent but gentle force.
* Apply C-Clamp (if necessary): If tapping doesn't work, carefully clamp a C-clamp on the rotor, applying pressure to pull it away from the hub. Be cautious not to damage the rotor or the hub.
5. Cleaning and Inspection:
* Once the rotor is removed, clean the hub mating surface thoroughly to remove any rust or corrosion. This is crucial for a proper fit when installing the new rotor.
* Inspect the hub for any damage.
6. Install New Rotor:
* Install the new rotor, ensuring a clean and snug fit.
If you are still having trouble:
* Professional Help: If you can't remove the rotor yourself, it's best to take your car to a mechanic. A stuck rotor can be very stubborn, and forcing it can damage the hub or other components.
* Rust and Corrosion: Severe rust and corrosion can make this extremely difficult. The penetrating oil step is critical, and allowing ample time for it to soak is key. You might need to repeat the penetration and tapping steps several times.
Remember to consult a repair manual specific to your 1991 Dodge Stealth. It will provide detailed diagrams and torque specifications for all the bolts and components involved. Improper torque can damage your brake system. If you're unsure about any step, seeking professional help is always the safest option.
