Front Disk Brake Rotor and Caliper Replacement
Remove caliper and set aside. Zip ties may be used to hang the caliper from the vehicle.
Remove the free running hub assembly.
Remove the snap-ring and drive clutch.
Remove the lock washer.
Using a suitable tool, remove the wheel bearing lock nut.
Remove the wheel bearing.
Carefully remove the rotor-hub assembly.
Separate the hub and rotor.
Install hub on new rotor. 71ft-lb
Apply grease to the wheel bearings, the center of the wheel hub, grease seal and spindle.
Install the hub/rotor assembly, wheel bearings, lock nut and torque to 72ft-lb.
Loosen the bearing lock nut, then torque to 1ft-lb.
Spin the hub several times in both directions and torque to 72ft-lb.
Loosen bearing lock nut again, then torque to 1ft-lb.
Spin the hub several times in both directions.
Install lock washer. If holes do not line up, turn the lock nut 15 - 30 degrees to fit.
Install drive clutch and snap-ring and the free running hub assembly.
Mount loaded caliper on spindle and torque to 72ft-lb.
Remove brake line from old caliper and install to new using new rings and torque to 14ft-lb.
Install one-man-bleeder valve on bleeder screw and run exit line to catch pan.
Make sure brake fluid level is high at the master cylinder.
Pump brakes 2-3 times.
Loosen bleeder screw 1 1/2 turns.
Pump brakes 4-6 times.
Repeat as necessary until air is removed from lines, then tighten bleeder screw.
Repeat process for opposite side.
The rotors come with a protective coating from the factory to prevent corrosion during shipping. Perform the following procedure to bed-in the brake pads.
Find a road with no interfering traffic. Perform 10 moderate stops from 55-0 MPH. After the tenth stop, cool the brakes by either parking the vehicle for 3 hours or driving 15-20 miles at normal speed without stopping.
