Brake Disc (Rotor)

REMOVAL & INSTALLATION

Front

1991–1994 MODELS

1. Raise the vehicle and support it safely.
2. Remove the wheel and tire assembly.
3. Remove the brake caliper.

   Fig. 1: Remove and support the brake caliper

4. On 2WD vehicles, remove the grease cap, cotter pin and nut from the hub. Remove the rotor from the vehicle.
5. On 4WD vehicles, remove the locknut and washer from the free wheeling hub. Remove the adjusting nut and thrust washer. Remove the hub with disc together with the outer bearing.

   Fig. 2: Pull the front rotor off the hub

   To install:

6. Before installing the rotor, thoroughly clean and repack the wheel bearings, using MP grease. Coat inside the hub and cap with MP grease.
7. Install a new bearing seal. Coat the seal lip with Multi Purpose grease.
8. On 2WD vehicles, install the rotor, outer bearing and thrust washer. Adjust the bearing preload.
9. On 4WD vehicles, install the free wheeling hub locknut and washer. Adjust the preload and check that the bearing has no play. Secure the lock nut by bending one of the lock washer teeth inward and the other lock washer teeth outward.
10. On 2WD vehicles, install the locknut, cotter pin and hub grease cap.
11. On 4WD vehicles, install the free wheeling hub or automatic locking hub.
12. Install the brake caliper.
13. Install the wheel and tire assembly.
14. Check and adjust the brake fluid level.
15. Road test the vehicle for proper operation.

1995–97 MODELS

1. Disconnect the negative battery cable to the battery.
2. Loosen the wheel lugs slightly, then raise and safely support the vehicle.
3. Remove the wheel(s) and temporarily install two of the wheel lug nuts.
4. Hold the sliding pin on the bottom with a wrench and loosen the installation bolt.
5. Remove the two installation bolts holding the caliper to the torque plate.
6. Remove the caliper from the torque plate and hang the caliper from a piece of wire. Do not disconnect the brake hose.

   WARNING
   Do not allow the caliper to hang freely from the vehicle. Always support the caliper with a wire from the vehicle.

7. Unbolt and remove the torque plate.
8. Remove the two wheel nuts and pull the disc from the axle hub.

   To install:

9. Position the new rotor disc onto the hub and reinstall the two wheel nuts temporarily.
10. Install the torque plate onto the vehicle. Tighten the two torque plate bolts to 65 ft. lbs. (88 Nm). Make sure the brake pads are seated correctly within the torque plate.
11. Install the caliper to the torque plate. Tighten the installation bolts to 27 ft. lbs. (36 Nm).
12. Remove the wheel lug nuts and install the wheels. Secure the wheel lugs.
13. Lower the vehicle and tighten the lug nuts. Before moving the vehicle, make sure to pump the brake pedal to seat the brake pads against the rotors.
14. Connect the negative battery cable to the battery.

Rear

1. Loosen the rear lugnuts and raise and support the vehicle.
2. Remove the rear wheel.
3. Raise and support the caliper assembly.
4. If necessary, remove the adjuster rubber cover and adjust the parking brake to create some slack in the line.

   Fig. 3: Placing two bolts in the rotor and pulling them may ease rotor removal

5. Slide the rotor off the hub.

   Fig. 4: Slide the rotor off the rear axle hub

   To install:

6. Position the disc onto the hub.
7. Lower the caliper and secure.
8. Install the rear wheel.
9. Lower the vehicle, install the lugnuts and tighten to 76 ft. lbs. (103 Nm).
10. Adjust the parking brake, if necessary.