Tools You'll Need:
* Jack and Jack Stands: Essential for safety. Never work under a vehicle supported only by a jack.
* Lug Wrench: To remove the wheels.
* Wheel Chocks: To secure the vehicle.
* Socket Wrench and Sockets: You'll need sockets that fit the lug nuts and caliper mounting bolts.
* Caliper Compression Tool: This tool is crucial to compress the caliper piston. A C-clamp can sometimes work in a pinch, but a dedicated tool is safer and easier.
* Hammer (Optional): May be needed to tap the rotor loose if it's stuck.
* Wrench (Optional): May be needed for caliper mounting bolts depending on the design.
* Penetrating Oil (Optional): Helpful if bolts are rusty or seized.
Steps:
1. Safety First: Park on a level surface, engage the parking brake firmly, and chock the rear wheels. Raise the front of the truck using the jack and securely place it on jack stands.
2. Remove the Wheel: Remove the lug nuts and carefully take off the wheel.
3. Remove the Caliper:
* Locate the caliper mounting bolts (usually two). Apply penetrating oil if needed and allow it to soak for a few minutes.
* Use a wrench or socket to carefully loosen and remove the caliper mounting bolts.
* Gently hang the caliper using a piece of wire or a bungee cord to keep it out of the way. Do *not* let it dangle by the brake line.
4. Compress the Caliper Piston: Using the caliper compression tool, slowly and steadily compress the caliper piston. This will create space to remove the rotor. You may need to rotate the piston as you compress it to allow it to retract evenly.
5. Remove the Rotor: The rotor should now be free to slide off the wheel hub. If it's stuck, gently tap it around its circumference with a rubber mallet or a hammer wrapped in cloth to avoid damaging the rotor. Avoid hitting the hub.
6. Clean the Hub: Clean the wheel hub thoroughly to remove any rust or debris.
7. Install the New Rotor (if applicable): Slide the new rotor onto the hub. Ensure it sits flush and makes good contact.
8. Reassembly:
* Reinstall the caliper.
* Tighten the caliper mounting bolts to the manufacturer's specified torque.
* Remove the wire or bungee cord holding the caliper.
* Reinstall the wheel and tighten the lug nuts to the manufacturer's specified torque. Do this in a star pattern to ensure even tightening.
* Lower the vehicle.
9. Test: Pump the brakes several times to ensure proper caliper engagement. Then test drive the vehicle to ensure there's no unusual noise or vibration.
Important Considerations:
* Rust and Seized Components: If bolts are heavily rusted or seized, be extremely careful to avoid stripping them. Penetrating oil and patience are your best friends. If you're having trouble, consider professional help.
* Brake Fluid: If you have to open the brake system (e.g., for a major brake job), remember to bleed the brakes after reassembly to remove any air that may have entered the system.
* Torque Specifications: Always refer to your owner's manual or a repair manual for the correct torque specifications for the lug nuts and caliper mounting bolts. Over-tightening can damage components.
This is a general guide; variations might exist depending on your specific 1994 Ford Ranger model and trim level. If you are unsure about any step, it's best to consult a qualified mechanic. Working on brakes is crucial for safety, and improper repair can lead to serious consequences.
