Tools You'll Need:
* Jack and jack stands: Safely lift the Bronco and support it securely. Never work under a vehicle supported only by a jack.
* Lug wrench: To remove the wheel.
* Wheel chocks: To prevent the vehicle from rolling.
* Sockets and wrench: The size will depend on your Bronco, but you'll likely need sockets for caliper bolts, and possibly a wrench for the caliper bracket bolts. Consult your owner's manual or a repair manual for specific sizes.
* Hammer (optional): May be needed to gently tap the rotor loose.
* C-clamp or rotor removal tool (recommended): This makes removing the rotor much easier and safer than hammering. A lug wrench can sometimes be improvised as a rotor removal tool.
* Penetrating lubricant (like PB Blaster): Helps loosen rusted or stuck bolts.
* Gloves and safety glasses: Protect yourself from dirt, grease, and potential injury.
Steps:
1. Safety First: Park on a level surface, engage the parking brake, and chock the wheels. Lift the Bronco using the jack and securely place it on jack stands.
2. Remove the Wheel: Remove the lug nuts and take off the wheel.
3. Remove the Caliper:
* Option 1 (most common): Many Broncos use a sliding caliper. You'll need to locate the caliper bolts (usually two) on the caliper bracket. Apply penetrating lubricant if necessary. Unscrew the bolts and carefully support the caliper with a bungee cord or wire to prevent it from hanging by the brake line. Do *not* disconnect the brake line unless absolutely necessary.
* Option 2 (less common): Some models may have a fixed caliper. This requires removing the caliper mounting bracket bolts, then removing the caliper assembly. Consult a repair manual for your specific model.
4. Remove the Brake Pads (optional, but recommended): While you have access, it's a good idea to inspect your brake pads. If they're worn, replace them now. This also makes removing the rotor easier.
5. Remove the Rotor: This is where the C-clamp or rotor removal tool comes in handy. Position the tool between the rotor's mounting surface and the hub. Carefully tighten the clamp, applying even pressure to pull the rotor away from the hub. If the rotor is stuck, use gentle tapping with a hammer on the rotor's outer edge (avoid damaging the hub). *Never* hit the rotor directly against the hub; use a block of wood to protect the hub if hammering.
6. Inspect the Hub: Once the rotor is off, inspect the wheel hub for any damage, rust, or excessive wear. Clean it if needed.
7. Install New Rotor (if applicable): If installing a new rotor, ensure it's the correct one for your vehicle. Usually, the rotor slides directly onto the wheel studs.
8. Reassembly: Reinstall everything in reverse order. Make sure to tighten all bolts to the manufacturer's specifications (consult your owner's manual or a repair manual). Bleed the brakes after reassembly if you disconnected the brake lines or if the caliper was completely removed.
Important Considerations:
* Rust: If bolts are severely rusted, they might break. Use plenty of penetrating lubricant and be prepared to deal with broken bolts if necessary.
* Brake Fluid: Brake fluid is corrosive. Clean up any spills immediately.
* Torque Specifications: Always torque bolts to the manufacturer's specifications. Over-tightening can damage parts; under-tightening can lead to loose components.
* Repair Manual: A repair manual specific to your 1994 Ford Bronco will provide detailed diagrams and torque specifications. This is highly recommended, especially if you're not experienced with this type of repair.
Remember, if you're not comfortable performing this repair yourself, take your Bronco to a qualified mechanic. Improperly installed brakes can be extremely dangerous.
