Tools You'll Need:
* Jack and jack stands
* Lug wrench
* Wheel chocks
* Socket wrench and sockets (various sizes, including likely a 1/2" drive for lug nuts and possibly a 3/8" drive for caliper bolts)
* Wrenches (possibly open-ended and/or box-end)
* C-clamp or caliper compression tool
* Wire or zip ties (to hold the caliper out of the way)
* Brake cleaner
* Penetrating oil (like PB Blaster)
* Rotor puller (sometimes needed, but not always)
* Gloves
Procedure:
1. Safety First: Park on a level surface, engage the parking brake, chock the rear wheels, and use jack stands to securely lift the front of the truck. Never work under a vehicle supported only by a jack.
2. Remove the Wheel: Remove the lug nuts and take off the wheel.
3. Remove the Caliper:
* Locate the Caliper Bolts: Find the bolts holding the caliper to the caliper bracket. They are usually on the back side of the caliper.
* Apply Penetrating Oil (if needed): If the bolts are rusty or seized, spray penetrating oil on them and let it sit for a few minutes.
* Remove the Bolts: Carefully remove the bolts using the appropriate socket wrench.
* Support the Caliper: Once the bolts are out, the caliper will be hanging by the brake hose. You can either use a wire or zip tie to secure it to something nearby (like the suspension or spring) or use a C-clamp to compress the caliper piston and allow the caliper to hang freely without putting stress on the brake hose. Never let the caliper hang by the brake hose alone. Damage to the hose can lead to brake failure.
4. Remove the Caliper Bracket (if necessary): Some F-250s might require removing the caliper bracket (the metal piece the caliper bolts onto) to access the rotor. This usually involves removing more bolts. Again, check your repair manual.
5. Remove the Rotor:
* Inspect the Rotor: Look for any retaining clips, screws, or other fasteners holding the rotor to the wheel hub. Some rotors might have a single center bolt that needs removal.
* Rotor Puller (If Necessary): If the rotor is stuck, use a rotor puller. These tools are inexpensive and available at most auto parts stores. They are carefully inserted and tightened to pull the rotor off the hub. Never strike the rotor with a hammer or pry against it.
* Remove by Hand (If Possible): If no retaining clips or screws are present, the rotor should be able to be pulled off by hand.
6. Clean the Hub: Clean the wheel hub thoroughly with a wire brush and brake cleaner, removing any rust or debris.
7. Install the New Rotor (Reverse Order): Install the new rotor, ensuring it slides on smoothly. If you removed the caliper bracket, reinstall it and torque the bolts to the specifications in your repair manual. Reinstall the caliper, making sure the caliper piston is properly compressed. Torque the caliper bolts to the specified torque.
8. Reinstall the Wheel and Lug Nuts: Mount the wheel and tighten the lug nuts. Lower the vehicle. Tighten lug nuts fully after lowering.
Important Notes:
* Brake Fluid: Compressing the caliper piston will push brake fluid back into the master cylinder. Make sure the brake fluid reservoir is full. You might need to bleed the brakes after this job to remove any air that may have entered the system.
* Repair Manual: This is a general guideline. Always refer to a repair manual specific to your 1984 Ford F-250 4x4 for detailed instructions and torque specifications. Incorrect torque can damage components and compromise safety.
* Rust and Seized Parts: On older vehicles, rusted or seized parts are common. Patience and penetrating oil are your friends. If parts are severely damaged, they may need replacement.
If you are uncomfortable performing this repair yourself, it's best to take your vehicle to a qualified mechanic. Brake systems are critical for safety, and improper repair can have serious consequences.
