Tools You'll Need:
* Wheel chocks: Essential for safety.
* Jack and jack stands: Never work under a vehicle supported only by a jack.
* Lug wrench: To remove the wheels.
* Socket wrench and sockets: Appropriate sizes for your lug nuts, caliper bolts, and possibly rotor retaining bolts (if applicable).
* C-clamp or caliper compression tool: To compress the caliper piston.
* Wire or a bungee cord: To hold the caliper out of the way.
* Penetrating oil (PB Blaster, etc.): To help loosen rusted bolts.
* Clean rags or shop towels: To keep things clean.
* Torque wrench: To properly tighten bolts after reassembly.
Procedure:
1. Safety First: Park the Bronco on a level surface, engage the parking brake, and chock the rear wheels. Raise the front of the Bronco using the jack and securely support it with jack stands.
2. Remove the Wheel: Remove the lug nuts and carefully take off the wheel.
3. Remove the Caliper:
* Locate the caliper bolts: These are usually on the back of the caliper. Spray penetrating oil on them if they appear rusty.
* Compress the caliper piston: Use a C-clamp or caliper compression tool to push the piston back into the caliper. This creates space to remove the rotor. Be careful not to damage the piston seal or boot.
* Remove the caliper bolts: Unscrew the bolts and carefully remove the caliper. Use the wire or bungee cord to secure the caliper to the suspension, preventing it from hanging by the brake line.
4. Remove the Rotor:
* Inspect for retaining bolts or clips: Some Broncos may have retaining bolts or clips holding the rotor to the hub. Remove these if present.
* Remove the rotor: Generally, the rotor should now slide off the hub. If it's stuck, gently tap it with a rubber mallet or block of wood to loosen it. Avoid damaging the rotor's surface.
5. Clean the Hub: Clean the hub mating surface thoroughly before installing the new rotor.
6. Install the new rotor (Reverse the process): Install the new rotor, ensuring it's properly seated. Reinstall any retaining bolts or clips. Reinstall the caliper, ensuring it's properly aligned and the caliper bolts are tightened to the correct torque specification.
7. Reinstall the Wheel: Replace the wheel and tighten the lug nuts to the manufacturer's specified torque.
8. Lower the Vehicle: Carefully lower the Bronco from the jack stands.
9. Test the Brakes: Before driving, pump the brake pedal several times to ensure the brakes are working properly. A test drive is recommended to check for any unusual noises or vibrations.
Important Notes:
* Rust: If bolts are severely rusted, you may need to use a combination of penetrating oil and heat (carefully!) to break them loose. In extreme cases, you might need to drill them out.
* Brake Fluid: Be careful not to spill brake fluid. If you do, clean it up immediately, as it can damage paint.
* Torque Specifications: Always refer to your owner's manual or a reliable repair manual for the correct torque specifications for all bolts. Over-tightening can damage components.
* Professional Help: If you're uncomfortable performing this repair yourself, it's always best to take your Bronco to a qualified mechanic.
This guide provides a general overview. Specific procedures might vary slightly depending on your Bronco's model and condition. Always prioritize safety and consult appropriate repair manuals for detailed instructions and torque specifications specific to your vehicle.
