1. Preparation:
* Safety First: This involves jacking up the vehicle. Use jack stands – *never* work under a vehicle supported only by a jack. Wear safety glasses and gloves.
* Gather Tools: You'll need:
* Jack and jack stands
* Lug wrench
* Wheel chocks
* Socket wrench set (metric) – likely 14mm and 17mm will be needed, but check your vehicle's specifications.
* Torque wrench (crucial for proper tightening)
* C-clamp or rotor compressor (highly recommended to compress the caliper piston)
* Brake cleaner
* Wire brush
* Penetrating lubricant (like PB Blaster)
* New brake rotors (ensure they're the correct size for your vehicle – check your owner's manual or a parts store)
* New brake pads (it's generally recommended to replace pads when changing rotors)
* Optional: A caliper piston wind-back tool (makes compressing the piston much easier)
2. Removing the Wheel:
* Chock the wheels on the opposite side of the vehicle to prevent it from rolling.
* Loosen the lug nuts slightly with the lug wrench *before* jacking up the vehicle.
* Jack up the vehicle securely and place it on jack stands.
* Remove the lug nuts completely and remove the wheel.
3. Removing the Caliper and Brake Pads:
* Locate the caliper mounting bolts: These are typically 14mm or 17mm bolts, located on the back of the caliper.
* Spray penetrating lubricant: Apply penetrating lubricant to the bolts to loosen them.
* Remove the caliper mounting bolts: Carefully remove the bolts and support the caliper. You can usually hang the caliper from the spring using a bungee cord or wire to prevent it from dangling and stressing the brake line. *Do not let the brake line hang freely.*
* Remove the brake pads: These will usually just slide out of their holders. Take note of how they are oriented and try to keep them together for re-installation.
* Compress the caliper piston: This is necessary to allow the new, thicker rotor to fit. Use a C-clamp or rotor compressor to slowly and evenly compress the piston. A wind-back tool is far easier and prevents damage to the piston. It’s essential to keep the piston moving straight so you don't damage the piston seals.
4. Removing the Old Rotor:
* Remove the rotor mounting bolts (if any): Some Tracker models have bolts securing the rotor to the hub. Others may be pressed on. If it's bolted on, remove the bolts.
* If pressed on: Use a rubber mallet to gently tap the rotor off the hub. It may require a bit of persuasion. If it's stuck really firmly, consider using a puller tool.
5. Installing the New Rotor:
* Clean the hub: Thoroughly clean the wheel hub with a wire brush and brake cleaner to remove any rust or debris.
* Install the new rotor: If bolted on, install and tighten the bolts to the manufacturer's specified torque. If pressed on, carefully slide the rotor onto the hub. Ensure a smooth, even fit.
* Install the brake pads: Put the new brake pads back into their holders, paying attention to their orientation (there might be wear sensors).
6. Reassembly:
* Install the caliper: Carefully mount the caliper back onto the caliper bracket. Make sure it’s aligned properly.
* Tighten the caliper bolts: Tighten the caliper mounting bolts to the manufacturer's specified torque.
* Install the wheel: Replace the wheel and tighten the lug nuts hand tight, then using a lug wrench tighten them to the manufacturer's specified torque in a star pattern (opposite nuts first, then adjacent nuts).
* Lower the vehicle: Carefully lower the vehicle using the jack.
* Final tightening of lug nuts: Double-check the lug nuts for tightness.
7. Final Steps:
* Pump the brake pedal: Pump the brake pedal several times to restore pressure in the system.
* Test drive: Take a short test drive to ensure the brakes are working correctly.
Important Notes:
* Consult your owner's manual: This is crucial for specific torque specifications and other model-specific information.
* Brake fluid: If you're completely removing the caliper, be prepared for a small amount of brake fluid to leak. Have some rags handy. If you are concerned, consult a professional.
* Professional Help: If you are uncomfortable with any part of this process, it's best to take your vehicle to a qualified mechanic. Improper brake work can be extremely dangerous.
This is a general guide. The exact procedure might vary slightly depending on your specific 2003 Chevy Tracker model. Always refer to a repair manual specific to your vehicle for detailed instructions and torque specifications. Safety is paramount when working on your brakes.
