Here's a general overview of the process. Specific steps may vary slightly depending on your Intrepid's trim level and options. Always consult a repair manual specific to your vehicle for detailed instructions and torque specifications. A Haynes or Chilton manual is a good investment.
Tools You'll Need:
* Jack and jack stands: Essential for safely lifting the vehicle. Never work under a car supported only by a jack.
* Lug wrench: To remove the wheels.
* Wheel chocks: To prevent the car from rolling.
* Socket wrench set: Various sizes, including metric and possibly SAE, depending on your Intrepid.
* Torque wrench: Crucial for tightening bolts to the correct specifications. Incorrect torque can lead to brake failure.
* Caliper piston compressor tool: Needed to push the caliper piston back into the caliper bore to make room for the new rotor. A C-clamp can sometimes work in a pinch, but a dedicated tool is safer and easier.
* Wrench or socket to remove caliper mounting bolts.
* Hammer (optional): Might be needed to help break loose stubborn bolts.
* Penetrating oil (like PB Blaster): Helpful for loosening rusted bolts.
* Clean rags or shop towels: To keep things clean.
* New front brake rotors: Make sure you get the correct ones for your Intrepid.
* New brake pads (recommended): While not strictly necessary, it's highly advisable to replace the brake pads at the same time as the rotors for optimal braking performance and even wear.
* Safety glasses and gloves: Always protect yourself.
Steps (General):
1. Safety First: Park on a level surface, engage the parking brake, and chock the rear wheels. Wear safety glasses and gloves.
2. Lift and Support: Safely lift the vehicle using the jack and secure it with jack stands.
3. Remove Wheels: Remove the lug nuts and carefully remove the wheels.
4. Remove Caliper: Remove the caliper mounting bolts and carefully remove the caliper assembly. You may need to support the caliper with a bungee cord or wire to keep it from hanging by the brake line.
5. Compress Caliper Piston: Use the caliper piston compressor tool to slowly and evenly compress the piston back into the caliper bore. This makes room for the new, thicker rotor.
6. Remove Old Rotor: The old rotor may be held on by a single bolt or just friction. Remove the old rotor. Clean the hub thoroughly.
7. Install New Rotor: Install the new rotor onto the wheel hub.
8. Reinstall Caliper: Reinstall the caliper assembly, ensuring the brake pads are correctly positioned against the rotor.
9. Reinstall Wheel: Reinstall the wheel and tighten the lug nuts to the proper torque specification (check your repair manual).
10. Lower Vehicle: Carefully lower the vehicle.
11. Test Brakes: Carefully test the brakes. Pump the brake pedal several times to build up pressure and ensure the brakes work correctly. If you feel any sponginess or unusual resistance, have the brakes checked by a mechanic immediately.
Important Considerations:
* Torque Specifications: Always tighten bolts to the manufacturer's recommended torque specifications. Using a torque wrench is essential to avoid damage and ensure safety.
* Brake Fluid: If you open the brake system, you might need to bleed the brakes afterwards to remove any air that might have entered the lines. This is a separate procedure that should be done correctly.
* Rust: If the bolts are rusted or seized, use penetrating oil and allow sufficient time to work before attempting to remove them. Avoid excessive force, as you could strip the bolt heads.
This is a simplified overview. Refer to a repair manual for your specific 1997 Dodge Intrepid for detailed instructions, diagrams, and torque specifications. If you are unsure about any step, seek professional help. Incorrect brake work can lead to serious injury or death.
