1. Safety First:
* Engage the parking brake firmly. This is crucial to prevent the vehicle from rolling.
* Use jack stands. Never work under a vehicle supported only by a jack.
* Wear safety glasses. Rust can fly up when you're working.
* Use gloves. Protect your hands from rust and grease.
2. Gather Your Tools:
* Wheel chocks: For extra safety.
* Jack and jack stands: To lift the vehicle.
* Lug wrench: To remove the wheel.
* Socket wrench set (metric): You'll need various sizes, including likely a 15mm or 17mm for caliper bolts, and possibly a 19mm or 21mm for the wheel nuts (check your owner's manual).
* Hammer: May be needed to help break loose stubborn parts.
* Penetrating lubricant (PB Blaster or similar): Spray generously on all bolts and connections at least 30 minutes before you start. This is your best friend in this situation.
* C-clamp or brake caliper compression tool: To compress the brake caliper piston.
* Wire brush: To clean off loose rust.
* Rotor removal tool (optional but recommended): These tools make rotor removal much easier, especially with stubborn rotors. They usually have a screw that pulls the rotor off the hub.
3. Procedure:
* Remove the wheel: Chock the opposite wheel, loosen the lug nuts slightly, jack up the vehicle, securely place it on jack stands, and then remove the lug nuts and wheel completely.
* Remove the brake caliper: Locate the caliper bolts (usually two). Spray them generously with penetrating lubricant. Use the appropriate socket wrench to remove them. Carefully support the caliper with a wire or bungee cord to prevent it from hanging by the brake line. Do *not* let the brake line dangle freely.
* Compress the caliper piston: Use the C-clamp or compression tool to compress the caliper piston. This will give you enough clearance to remove the rotor. Some pistons may require a turning motion as well as compression. Go slowly to avoid damaging the piston seals.
* Remove the rotor: If the rotor is particularly stubborn, use a wire brush to remove any loose rust from the hub and mating surface of the rotor. Spray more lubricant if needed. If you have a rotor removal tool, use it. If not, carefully pry the rotor off the hub using a hammer and a suitable metal punch or pry bar. Be cautious to avoid damaging the hub. Tap gently and evenly around the rotor. Excessive force can damage the hub.
* Clean the hub: Once the rotor is off, thoroughly clean the hub mating surface. Remove any rust, debris, or old brake pad material. A wire brush and brake cleaner are useful here.
4. Installation (of new rotors):
* Install new rotors. Usually, they simply slide onto the hub. They should fit snugly.
* Re-assemble the caliper and brake pads making sure everything is correctly aligned and the caliper piston moves freely.
* Replace the wheel and tighten the lug nuts to specification (check your owner's manual).
* Lower the vehicle.
Important Considerations:
* Rust is your enemy: Penetrating lubricant is essential. Give it ample time to work.
* Don't force anything: If something is stuck, reassess your approach rather than using excessive force. You risk damaging components.
* Brake system is critical: If you're not comfortable doing this yourself, take it to a qualified mechanic.
This is a general guide. The exact procedure and bolt sizes might vary slightly depending on your specific 2002 Dodge Ram 1500 model. Always consult your owner's manual for specific instructions and torque specifications. Remember safety is paramount. If in doubt, consult a professional mechanic.
