Here's a general outline. Specifics may vary slightly depending on your exact truck's configuration and the tools you have available. Consult a repair manual specific to your year and model for detailed diagrams and torque specifications.
1. Preparation:
* Gather Tools: You'll need a jack, jack stands, lug wrench, wheel chocks, socket wrench set (metric), torque wrench, brake caliper piston compression tool, wire brush or brake cleaner, possibly a C-clamp (depending on the caliper design), rotor removal tool (if needed), and new rotors.
* Safety First: Park on a level surface, engage the parking brake, and use wheel chocks on the rear wheels.
2. Remove the Wheel:
* Loosen the lug nuts slightly with the lug wrench before jacking up the vehicle.
* Safely jack up the truck and secure it on jack stands.
* 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.
* Remove the caliper bolts: Use the appropriate socket wrench to remove them.
* Support the caliper: You'll need to either hang the caliper from a wire or use a bungee cord to keep it from dangling and stressing the brake line. Do not let the brake line hang freely.
* Compress the caliper piston: Use a caliper piston compression tool to push the piston back into the caliper. This creates space to accommodate the new, thicker rotor. This is crucial, otherwise the caliper won't fit over the new rotor.
4. Remove the Rotor:
* Inspect for rust or corrosion: There might be significant rust between the rotor and the wheel hub. Use a wire brush or penetrating lubricant to loosen it.
* Remove the rotor: Some rotors simply slide off the wheel studs. Others might require a rotor removal tool (a slide hammer is common). If it's stuck, tap gently around the edges with a hammer and punch (be careful not to damage the hub).
5. Install the New Rotor:
* Clean the hub: Ensure the wheel hub mating surface is clean and free of debris.
* Install the new rotor: Slide the new rotor onto the wheel studs. It should fit snugly.
6. Reassemble:
* Install the caliper: Carefully position the caliper over the new rotor and reinstall the caliper bolts. Tighten them to the manufacturer's specified torque.
* Reinstall the wheel: Put the wheel back on and tighten the lug nuts in a star pattern (opposite nuts first, then the ones in between) to avoid warping the rotor.
* Lower the vehicle: Carefully lower the truck from the jack stands.
* Torque the lug nuts: Use a torque wrench to tighten the lug nuts to the manufacturer's specified torque.
7. Bleed the Brakes (Important!):
* After replacing the rotors, you may need to bleed the brakes to remove any air that might have entered the brake lines during the process. Refer to your owner's manual or a repair guide for the proper brake bleeding procedure. This step is vital for proper braking performance.
Important Considerations:
* Torque Specifications: Always refer to your owner's manual or a repair manual for the correct torque specifications for the lug nuts and caliper bolts. Incorrect torque can lead to problems.
* Brake Pad Inspection: While you're at it, inspect your brake pads. If they're worn, replace them as well. Replacing rotors without replacing worn pads is wasteful.
* Hub Inspection: Check the wheel hub for damage, excessive play, or rust. If there's anything questionable, it should be addressed.
This is a general guide. Consult a repair manual specific to your 1996 Chevy Sierra for detailed instructions and torque specifications. If you're uncomfortable with any part of this process, take your truck to a qualified mechanic. Improper brake work can be dangerous.
