Tools You'll Need:
* Jack and jack stands
* Wheel chocks
* Lug wrench
* Socket wrench with appropriate sockets (likely 14mm for the caliper bolts, and possibly others for the caliper bracket bolts)
* C-clamp or caliper compression tool (to compress the caliper piston)
* Wire or zip tie (to secure the caliper out of the way)
* Penetrating lubricant (like PB Blaster)
* Rotor removal tool (optional, but highly recommended to avoid damaging the rotor)
* Clean rags or shop towels
Steps:
1. Safety First: Park the truck on a level surface, engage the parking brake, and chock the rear wheels. Use the jack to lift the front of the truck, placing jack stands securely under the frame near the front axle *before* working under the vehicle.
2. Remove the Wheel: Loosen the lug nuts on the wheel using the lug wrench *before* lifting the truck. Once lifted, remove the lug nuts completely and take off the wheel.
3. Remove the Caliper:
* Locate the caliper bolts: These are usually on the back of the caliper. Apply penetrating lubricant to the bolts if they appear stuck.
* Remove the bolts: Carefully unscrew the caliper bolts using the appropriate socket wrench.
* Support the caliper: As you remove the bolts, carefully support the caliper with one hand to prevent it from hanging by the brake line.
* Compress the caliper piston: Use a C-clamp or caliper compression tool to push the piston back into the caliper housing. This creates space for the new, thicker rotor. Be careful not to damage the piston or the rubber boot.
* Secure the caliper: Use a wire or zip tie to securely attach the caliper to something nearby (like the suspension), keeping it out of the way but preventing strain on the brake line.
4. Remove the Caliper Bracket (If Necessary): Some models require removing the caliper bracket bolts before the rotor can be removed. These bolts are usually larger than the caliper bolts. If your vehicle has these bolts, remove them and support the bracket while you remove it.
5. Remove the Rotor: This is where a rotor removal tool is highly recommended. These tools help to prevent damage to the rotor and hub. If you don't have one, try gently tapping the rotor off with a hammer and a soft-faced mallet (wood or plastic). Be careful to avoid damaging the wheel studs.
6. Clean the Hub: Clean the wheel hub thoroughly of any rust, dirt, or debris.
7. Install the New Rotor: Install the new rotor, ensuring it sits flush against the hub. If using a rotor removal tool, reverse the process for installation.
8. Reassembly: Reverse the steps above to reinstall the caliper bracket (if removed), caliper, wheel, and lug nuts. Tighten the lug nuts in a star pattern to ensure even pressure. Lower the vehicle to the ground and torque the lug nuts to the manufacturer's specifications (usually found in your owner's manual).
9. Bleed the Brakes (Important!): After working on the brake system, you *must* bleed the brakes to remove any air that might have entered the lines. This is crucial for proper braking performance and safety.
Important Considerations:
* Rust: If bolts are rusted or seized, use penetrating lubricant and allow sufficient time for it to work before attempting to remove them. Excessive force can damage threads.
* Brake Fluid: Be careful not to spill brake fluid onto painted surfaces, as it can damage the paint.
* Torque Specifications: Always tighten bolts to the manufacturer's specified torque values. Over-tightening can strip threads or damage components, while under-tightening can lead to loose parts and potential safety hazards.
This guide is for informational purposes only. If you're not comfortable performing this repair yourself, take your vehicle to a qualified mechanic. Improper brake repair can be extremely dangerous.
