Here's a general procedure. Specific steps may vary slightly depending on your exact model and any modifications. Always consult a repair manual specific to your vehicle for the most accurate instructions.
Tools You'll Need:
* Jack and jack stands: To safely lift the vehicle.
* Lug wrench: To remove the wheel.
* Wheel chocks: To prevent the vehicle from rolling.
* Socket wrench and sockets: The sizes you'll need will depend on your car, but you'll likely need sockets for the lug nuts and caliper bolts.
* C-clamp or rotor puller: This is often necessary to remove stubborn rotors. A hammer and punch can *sometimes* work, but a puller is safer and less likely to damage the rotor or hub.
* Wrench or socket to remove caliper mounting bolts.
* Penetrating oil (like PB Blaster): To help loosen rusted or stuck bolts.
* Gloves: To protect your hands.
* Safety glasses: To protect your eyes.
Procedure:
1. Safety First: Park on a level surface, engage the parking brake, and chock the wheels opposite the one you're working on. Use jack stands to securely lift the vehicle after jacking it up.
2. Remove the Wheel: Remove the lug nuts and carefully take off the wheel.
3. Remove the Caliper:
* Locate the caliper mounting bolts: These are usually located on the back of the caliper.
* Apply penetrating oil: If the bolts are difficult to turn, spray them generously with penetrating oil and let it sit for a few minutes.
* Remove the caliper mounting bolts: Carefully unscrew the bolts and remove the caliper assembly. You may need to gently pry the caliper away from the rotor. Do not completely detach the brake line from the caliper. You can usually just hang the caliper using a wire or bungee cord to keep it out of the way, attached to the suspension or spring.
4. Remove the Brake Pads: You might need to remove the brake pads (at least partially) to allow easier rotor removal, especially if your caliper is a floating type.
5. Remove the Rotor:
* Inspect the rotor: Look for any retaining clips or screws holding the rotor to the hub. Some rotors have these; others rely on friction fit.
* If there are retaining clips or screws: Remove them.
* If it's a friction fit: Attempt to remove the rotor by hand. If it's stuck, use a rotor puller. A C-clamp can sometimes work by placing it across the rotor's lug holes and carefully pushing the rotor away from the hub. Avoid damaging the rotor or hub by using excessive force. A hammer and punch are a last resort and can easily damage components.
6. Clean the Hub: Clean the hub mating surface of any rust or debris before installing the new rotor.
7. Install the New Rotor (Reverse Order): Install the new rotor, ensuring it's seated properly, then reinstall the caliper, brake pads, and wheel. Torque lug nuts to the manufacturer's specifications.
Important Considerations:
* Rust: On older vehicles, rust can significantly hinder rotor removal. Penetrating oil is your friend. Be patient and allow it to work its magic.
* Caliper Piston: Sometimes the caliper piston needs to be compressed slightly to give you extra room for removal. However, never compress the caliper piston without the proper tools and knowledge. This is a potentially hazardous procedure.
* Brake Fluid: Brake fluid is corrosive. If any spills, clean it up immediately.
* Torque Specifications: Always tighten bolts and nuts to the manufacturer's specified torque. Consult your repair manual.
This is a general guide. Refer to a repair manual specific to your 1996 Lincoln Town Car for detailed instructions and torque specifications. If you're not comfortable performing this task yourself, take your vehicle to a qualified mechanic. Brake work is crucial for safety, and improper repair can be dangerous.
