Here's a general outline of the process. This is NOT a comprehensive guide and may not apply perfectly to all models of the 2002 Intrepid. Always consult a repair manual specific to your vehicle's year, make, and model for detailed instructions and torque specifications.
Tools You'll Need:
* Jack and jack stands: Crucial for safety. Never work under a car supported only by a jack.
* Lug wrench: To remove the wheels.
* Wheel chocks: To secure the other wheels.
* Socket wrench set: Including the correct size for your lug nuts and caliper bolts.
* C-clamp or caliper compression tool: To compress the caliper piston.
* Wrench or socket for caliper mounting bolts.
* Rotor removal tool (optional but recommended): Makes removing stubborn rotors easier. Some rotors can be removed by hand, while others require this tool.
* Clean rags or shop towels: To clean up brake dust and fluids.
* Penetrating lubricant (like PB Blaster): To help loosen rusty bolts.
* Torque wrench: Essential for properly tightening bolts to the manufacturer's specifications. Improper torque can lead to brake failure.
* New brake rotors: Make sure you get the correct ones for your vehicle.
Procedure:
1. Safety First: Park on a level surface, engage the parking brake, and use wheel chocks on the wheels that aren't being worked on.
2. Raise and Secure the Vehicle: Safely raise the front of the vehicle using the jack and secure it with jack stands.
3. Remove the Wheel: Remove the lug nuts and carefully remove the wheel.
4. Compress the Caliper Piston: Using the C-clamp or caliper compression tool, carefully compress the caliper piston. This will create the space needed to remove the rotor. Be careful not to damage the caliper piston seal. Some brake fluid might leak out – have rags ready.
5. Remove the Caliper: Once the piston is compressed enough, you may be able to remove the caliper bolts and carefully remove the caliper. You may need to carefully support the caliper with a bungee cord or wire to keep it out of the way.
6. Remove the Rotor: If the rotor doesn't slide off easily, use a rotor removal tool to gently tap it off the hub. Be careful not to damage the wheel studs.
7. Install the New Rotor: Clean the hub thoroughly before installing the new rotor. The new rotor should slide easily onto the hub.
8. Reinstall the Caliper: Reinstall the caliper and tighten the bolts to the correct torque specification (check your repair manual).
9. Reinstall the Wheel: Reinstall the wheel and tighten the lug nuts. Don't fully tighten them yet.
10. Lower the Vehicle: Lower the vehicle to the ground.
11. Final Tightening: Fully tighten the lug nuts in a star pattern.
12. Check for proper clearance: Ensure there's proper clearance between the rotor and the caliper.
13. Repeat for the other side: Repeat the process for the other front wheel.
14. Test Drive: After completing the work, test drive the vehicle to ensure the brakes are functioning correctly. Listen for any unusual noises and check for brake pulsation.
Important Considerations:
* Brake Fluid: You may need to bleed the brakes after replacing the rotors, depending on how much fluid was lost. This is a crucial step to prevent air in the brake lines, which can result in spongy brakes or brake failure.
* Repair Manual: A repair manual specific to your 2002 Dodge Intrepid is essential. It will have diagrams, torque specifications, and other critical information for your particular model.
* Wear Safety Glasses and Gloves: Protect your eyes and hands from sharp edges and brake dust.
This is a simplified overview. Improperly performing this task could lead to brake failure, resulting in serious injury or death. If you are not comfortable with any part of this process, please take your vehicle to a qualified mechanic.
