Tools You'll Need:
* Jack and jack stands: Essential for safely lifting the truck. Never work under a vehicle supported only by a jack.
* Wheel chocks: To prevent the truck from rolling.
* Lug wrench: To remove the wheels.
* Socket wrench set and ratchet: Various sizes, including those for lug nuts, caliper bolts, and rotor retaining hardware (if applicable).
* C-clamp or caliper compression tool: To compress the caliper piston.
* Wire or a bungee cord: To hold the caliper out of the way.
* Penetrating oil (like PB Blaster): To help loosen rusted bolts.
* Torque wrench: To tighten bolts to the correct specification.
* Clean rags or shop towels: To clean up brake dust and fluid.
* New brake rotors: Make sure you purchase the correct ones for your vehicle.
* Optional: Anti-seize lubricant: For caliper bolts and other fasteners to prevent future seizing.
Procedure:
1. Safety First: Engage the parking brake, chock the rear wheels, and wear safety glasses.
2. Lift and Secure: Jack up the front of the truck and securely place it on jack stands.
3. Remove the Wheel: Remove the lug nuts and take off the wheel.
4. Remove the Caliper:
* Use a socket wrench to remove the caliper mounting bolts. These are usually on the top and bottom of the caliper.
* Carefully remove the caliper from the rotor. Be aware that there is brake fluid inside the caliper; avoid spilling it. You may need to support the caliper to prevent it from dangling by a brake line. A wire or bungee cord can help.
5. Compress the Caliper Piston: Use a C-clamp or caliper compression tool to slowly compress the caliper piston. This will create space for the new, thicker rotor. Be careful not to damage the piston seal.
6. Remove the Old Rotor:
* Some Rangers might have a retaining bolt or clip holding the rotor to the wheel hub. If so, remove it.
* Often, the old rotor will just slide off the wheel studs. If it's stuck, gently tap it from the back with a rubber mallet to loosen it. Avoid damaging the wheel studs.
7. Install the New Rotor:
* Slide the new rotor onto the wheel studs. Ensure it's seated properly.
* If there was a retaining bolt or clip, reinstall it.
8. Reinstall the Caliper:
* Carefully reinstall the caliper over the new rotor.
* Tighten the caliper mounting bolts to the specified torque.
9. Reinstall the Wheel:
* Put the wheel back on and tighten the lug nuts. Don't overtighten yet.
10. Lower the Truck: Carefully lower the truck to the ground.
11. Tighten Lug Nuts: Tighten the lug nuts to the correct torque specification using a torque wrench.
12. Check for Clearance: Verify that the rotor spins freely and doesn't rub against the caliper.
13. Test Drive: Take a short test drive to ensure everything is working correctly. Pay close attention to braking performance and any unusual noises.
14. Brake Bleed (Possibly): While not always necessary, it's a good idea to bleed the brakes after replacing a rotor. Air may have gotten into the system during the process. Consult your repair manual for proper bleeding procedures.
Important Considerations:
* Rust: If bolts are severely rusted, they may break. Use penetrating oil liberally and allow it to soak in before attempting to remove them. If they break, you may need to extract the broken pieces.
* Brake Fluid: Brake fluid is corrosive. Clean up any spills immediately.
* Torque Specifications: Always use a torque wrench and follow the specified torque values for your vehicle. Overtightening can damage components.
* Professional Help: If you're uncomfortable performing this task yourself, it's best to take your vehicle to a qualified mechanic. Brake repairs are crucial for safety.
Remember, this is a general guide. Always refer to a repair manual specific to your 2001 Ford Ranger 4x4 for detailed instructions and torque specifications. Improper repair could compromise your braking system, leading to dangerous consequences.
