Tools You'll Likely Need:
* Jack and jack stands: To safely lift the van.
* Wheel chocks: To secure the other wheels.
* Lug wrench: To remove the wheel.
* Socket wrench and sockets: Various sizes, likely including one for the caliper bolts, and possibly a larger one for the axle nut (if you need to remove the hub).
* C-clamp or caliper compression tool: To compress the brake caliper piston.
* Hammer and punch (possibly): May be needed to break loose stubborn bolts or parts.
* Rotor removal tool (optional but recommended): These tools make removing stubborn rotors easier and prevent damage. A slide hammer style is particularly helpful.
* Penetrating oil (like PB Blaster): To loosen rusted or seized bolts.
* Torque wrench: To tighten bolts to the correct specifications.
* Gloves: To protect your hands.
* Repair manual specific to your 2004 Ram Van: This is crucial for detailed instructions and torque specs.
Procedure (General Steps):
1. Safety First: Park on a level surface, engage the parking brake, and chock the rear wheels. Raise the van using a jack and securely support it with jack stands. Remove the wheel.
2. Compress the Caliper Piston: Use a C-clamp or caliper compression tool to push the caliper piston back into the caliper bore. This will give you enough clearance to remove the rotor. Be careful not to damage the piston or seals. Some calipers can be rotated out of the way without compressing the piston.
3. Remove the Caliper: After piston compression, you might need to remove the caliper mounting bolts. Once these are out, carefully hang the caliper using some wire or a specialized caliper hanger tool to prevent damaging the brake line. Don't let the brake line dangle freely.
4. Remove the Rotor: Often, the rotor simply slides off the hub. However, if it's stuck, a rotor removal tool will make the process much easier and safer than using a hammer and punch. Be careful; some rotors have a small lip that may need to be carefully worked free.
5. Inspect the Hub and Bearings: While the rotor is off, inspect the wheel hub and bearings for wear or damage. If anything looks questionable, consider replacing them.
6. Install the New Rotor (Reverse Order): Once you've installed the new rotor, reassemble everything in the reverse order of removal. Make sure to tighten all bolts to the manufacturer's specified torque.
7. Bleed the Brakes (Important): After reinstalling the caliper, you'll likely need to bleed the brakes to remove any air that may have entered the system during the process. Consult your repair manual for the correct bleeding procedure.
Important Considerations:
* Seized Rotors: If the rotor is severely rusted or seized to the hub, you may need more aggressive techniques (like penetrating oil and gentle tapping) to remove it. Again, a rotor puller is highly recommended to avoid damage.
* Hub Assembly Removal (Unlikely but Possible): In some cases, the rotor might be integrated into the hub assembly. If so, you may need to remove the entire hub assembly which involves removing the axle nut – a more complex procedure. This is less common with most front brake setups.
Disclaimer: This is a general guide. Improper brake work can be dangerous. If you're uncomfortable performing this repair, take your van to a qualified mechanic. The information provided here is not a substitute for a professional repair manual specific to your vehicle.
