Tools You'll Need:
* Jack and jack stands (Essential for safety)
* Lug wrench
* Wheel chocks
* Socket wrench set (metric)
* Torque wrench
* Brake caliper piston compressor tool (C-clamp can work in a pinch, but a dedicated tool is better)
* Wire or zip ties
* Penetrating oil (like PB Blaster)
* Clean rags
* New brake rotors
* New brake pads (highly recommended, even if they seem okay)
* Possibly a rotor hub puller (depending on how stuck the rotor is)
Steps:
1. Safety First: Park on a level surface, engage the parking brake firmly, and chock the rear wheels. Use jack stands to securely lift the truck – never work under a vehicle supported only by a jack.
2. Remove the Wheel: Loosen the lug nuts slightly with the lug wrench before jacking up the vehicle. Once lifted and secured, remove the lug nuts completely and take off the wheel.
3. Remove the Caliper:
* Use a socket wrench to remove the caliper mounting bolts. These are usually two bolts.
* Carefully support the caliper with a wire or zip tie to keep it from hanging by the brake line. This prevents stress on the line. Don't let it dangle.
4. Remove the Brake Pads: The pads should now be visible. They typically slide out easily. If they're stuck, gently pry them free. Note their orientation; they often have a wear indicator on one side.
5. Compress the Caliper Piston: Use the caliper piston compressor tool to push the piston back into the caliper. This creates space for the new, thicker rotor. If using a C-clamp, be careful not to damage the piston or seals. Do this slowly and steadily.
6. Remove the Rotor: Sometimes, the rotor will simply slide off the hub. If it's stuck, you might need a rotor hub puller. If you don't have a puller, try tapping gently around the rotor's outer edge with a rubber mallet to break it free. Never hit the rotor directly with a hammer as this may damage it.
7. Clean the Hub: Clean the wheel hub thoroughly with a wire brush to remove any rust or debris. This ensures proper rotor seating.
8. Install the New Rotor: Slide the new rotor onto the hub. Ensure it sits flush against the hub.
9. Install the Brake Pads: Insert the new (or cleaned and inspected old) brake pads into their respective slots, ensuring they sit correctly.
10. Install the Caliper: Carefully remount the caliper onto the caliper mounting bracket. Tighten the caliper bolts to the manufacturer's specified torque (check your repair manual).
11. Replace the Wheel: Mount the wheel and tighten the lug nuts in a star pattern (opposite nuts first). Then, lower the vehicle to the ground and fully tighten the lug nuts to the manufacturer's specified torque.
12. Repeat for the Other Side: Follow steps 2-11 for the other front wheel.
13. Pump the Brakes: After reinstalling both wheels, pump the brake pedal several times to ensure the brakes engage properly. Check for leaks.
14. Test Drive: Carefully test drive the vehicle to ensure the brakes are working correctly.
Important Notes:
* Torque Specifications: Always consult your owner's manual or a repair manual for the correct torque specifications for the lug nuts and caliper bolts. Using the wrong torque can lead to unsafe conditions.
* Brake Fluid: If you had to significantly compress the caliper piston, you might need to check and top off your brake fluid reservoir. Brake fluid is corrosive; clean up any spills immediately.
* Professional Help: If you are not comfortable performing this repair yourself, it's best to take your vehicle to a qualified mechanic. Brake failure is a serious safety concern.
This guide provides a general overview. Always refer to a repair manual specific to your 1997 GM 4x4 truck model for detailed instructions and torque specifications. Safety should be your top priority throughout this process.
