Tools You'll Need:
* Jack and jack stands (crucial for safety!)
* Lug wrench
* Wheel chocks
* Socket wrench and sockets (sizes will depend on your vehicle – check your manual)
* C-clamp (optional, but recommended for easier caliper piston retraction)
* Pliers or a caliper compression tool
* Rotor removal tool (optional, but highly recommended – helps prevent rotor damage)
* Penetrating lubricant (like PB Blaster)
* Clean rags or shop towels
* Torque wrench
Procedure:
1. Safety First: Park on a level surface, engage the parking brake firmly, and chock the rear wheels. Raise the front of the truck securely using a jack and support it with jack stands. 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:
* Option 1 (Using a C-clamp): Use a C-clamp to compress the caliper piston. This allows you to push the piston back into the caliper. Be careful not to damage the piston seal. Some people use pliers instead of a C-clamp, however, a dedicated caliper compression tool will ensure less chance of damage.
* Option 2 (Using a Caliper Compression Tool): This is the preferred method as it's designed for the job and reduces the risk of damage. Follow the tool's instructions.
* Once the piston is compressed enough, you should be able to carefully lift the caliper away from the rotor and hang it out of the way using a bungee cord or wire. Make sure the brake line is not under tension or damaged.
4. Remove the Rotor:
* Some rotors can be removed by hand after the caliper is removed.
* If the rotor is stuck: Use a rotor removal tool. These tools are designed to prevent damage to the rotor and hub. Apply penetrating lubricant if needed and tap gently with a hammer, working your way around. Never hammer directly on the rotor's surface.
5. Clean Up: Clean the hub mating surface thoroughly using a wire brush or appropriate tool to remove any rust or debris.
6. Install New Rotor (if replacing): Install the new rotor onto the wheel studs.
7. Reinstall the Caliper: Reinstall the caliper, making sure the brake pads are properly seated against the rotor. Tighten the caliper bolts to the manufacturer's specified torque.
8. Reinstall the Wheel: Replace the wheel and tighten the lug nuts in a star pattern to the manufacturer's specified torque.
9. Lower the Vehicle: Carefully lower the vehicle from the jack stands.
10. Test Brakes: After reinstalling everything, test the brakes carefully to ensure proper function. Bleed the brakes if necessary (if you've worked on the brake system).
Important Considerations:
* Rust: If the rotor is severely rusted, it may be difficult to remove. Apply penetrating lubricant to help loosen it.
* Torque Specifications: Always consult your vehicle's repair manual for the correct torque specifications for lug nuts and caliper bolts. Using the wrong torque can lead to damage.
* Brake Fluid: Be careful not to spill brake fluid. If you do, clean it up immediately.
This is a general guide. Consult a qualified mechanic if you are uncomfortable performing this task yourself. Improperly performing brake work can lead to dangerous consequences.
