Brake rotor replacement

Personally I would replace both rotors to prevent a future brake imbalance.

* chock rear wheels, raise front of vehicle and place on stands.

* remove wheels, remove brake calliper and bracket assemblies.

* remove bearing hubs from axles, via removal of bearing adjustment nut

*remove hub seals, clean and inspect bearings, repack with HT bearing grease.

* the brake rotor bolts to the rear of the hub, you will have to remove and replace rotor to hubs, make sure all bolts are thread locked with loctite 263 and tensioned to spec.

* pack hub with grease, install seals, fitt hub assembly and adjust wheel bearing preload, install new split pins.

* fitt brake calliper and brackets, fit new brake pads,

* fitt wheels lower vehicle, test brake for function

Hope this helps..

TO CHANGE FRONT BRAKE ROTORS. FIRST YOU NEED TO SAFELY RAISE SUPPORT VECHICLE ON JACK STANDS.MAKE SURE VECHICLE PARKED ON LEVEL SOLID GROUND.YOU NEED TO REMOVE BRAKE CALIPER BOLTS AND THE CALIPER FROM THE KNUCKLE.DONT LET CALIPER HANG BY BRAKE HOSE USE A PIECE OF WIRE TO SUPPORT CALIPER.REMOVE THE DISC BRAKE ROTOR RETAINING SCREWS IF EQUIPPED.IF THE ROTOR WILL NOT EASILY PULL OFF,SCREW TWO 8MM BOLTS INTO THE DISC BRAKE REMOVAL HOLES AND TURN THE BOLTS TWO TURNS AT A TIME TO PRESS THE ROTOR FROM THE HUB.

Put the parking brake On and jack up the front of your SUV.

Remove the lug nuts and you will be able to remove the tire and rimm by sliding them off.Remove the spindle bolt located at the center of the rotor using an 36 mm socket(approx).

Remove the two nuts located behind the rotor (one at top and other at the bottom). This will enable you to remove the brake caliper.While removing it be careful that the caliper tube stays straight.

Slide under your passport and remove the 4 bolts behind the hub using an 12 mm(approx) wrench.Pull the hub assembly out and this will remove the hub rotor in some cases if you are using an tool for pulling the hub assembly out or you have to slide the rotor off the hub assembly.

Slide the new rotor into the hub assembly.Reinstall the brake caliper and make sure the caliper tube is not twisted. Replace the spindle bolt.

Front hub bearing, remove tire, remove caliper and caliper holding bracket, you do not have to remove brake caliper from brake hose, just set it aside, if 4X4 remove front axle nut that goes through center of rotor, also remove brake rotor, disconnect elec, A.B.S connector, remove three bolts on back side of hub bearing, remove hub bearing, some times you will need to knock hub bearing out with a hammer.Reverse to install new hub bearing.

No, but I would replace the rotors. Turning them usually winds up getting them warped as soon as they heat up and/or you hit a puddle of water..also, you will need a torque wrench and standard automotive tools, Jack and stands and a vice..

1 Place the Transfer shift in the 2H position.
Raise and support the front of the vehicle safely on jackstands.
2 Remove the wheel and tire assembly.
3 Loosen the hub to rotor retainer bolts.
4 Remove the brake caliper mounting bolts and carefully remove the caliper (along with the brake pads) from the rotor. Do not disconnect the brake line. 5 Secure the caliper out of the way with the flexible line still connected.

Once the hub/rotor is removed from the vehicle the wheel bearings may be cleaned and repacked or the bearings and races may be replaced. For more information, please refer to the wheel bearing procedures in General Information & Maintenance of this manual.

6 Remove the hub nut using hub wrench J-29020-A or equivalent.
7 Remove the hub cap assembly retainer bolts.
8 Remove the spindle nut, washers, and other components. Remove the hub/rotor, being careful not to drop the outer wheel bearings. As the hub/rotor is pulled forward, the outer wheel bearings will often fall forward.
9 Once the hub/rotor is removed, remove the retainer bolts securing the rotor and hub together. Inspect the hub and replace if needed.

To install:
1 With the rotor secured in a vise, attach the wheel hub to the rotor using the retainer bolts. Tighten the bolts to 47-58 ft. lbs. (61-75 Nm). Apply 2.12 oz. (60 gm) of grease to the hub before installing.
2 Carefully install the wheel hub/rotor over the spindle.
3 Install the bearings washers and other components. 4 Position the lock washer so the hub cap assembly bolt holes line up properly.
5 Install the spindle washer and nut and secure using hub wrench J-29020-A or equivalent. Preload the bearing to 3.31 lbs. (1.5 kg).
6 Install the inner cam and any shims. Install the hub cap assembly and secure in place with retainer bolts. 7 Tighten grade M8 bolts to 17-22 ft. lbs. (22-29 Nm), tighten grade M10 bolts to 40-47 ft. lbs. (52-61 Nm).
8 Install the brake caliper.
9 Install the tire and wheel assembly.
10 Remove the supports and carefully lower the vehicle.

Removal & Installation

1. Remove 2/3of the brake fluid from the master cylinder.
   
2. Raise and support the vehicle.
   
3. Remove the tire and wheel assembly.
   
4. Remove the front wheel hub extension (dual wheel vehicles only).
   
   • Insert a drift or large screwdriver through the brake caliper into one of the brake rotor vanes in order to prevent the rotor from turning.
     
   • Mark the relationship of the front wheel hub extension to the hub
     
   • Remove the front wheel hub extension bolts
     
   • Remove the front wheel hub extension from the vehicle. It may be necessary to tap around the perimeter of the hub extension with a rubber mallet to loosen it from the hub
     
5. Mark the relationship of the rotor to the hub.
   
6. Remove the caliper and mounting bracket as an assembly.
   
7. Hang the caliper and the mounting bracket assembly from the suspension using mechanics wire.
   
8. Remove the rotor.
   
9. If the rotor is difficult to remove due to corrosion in the hub area use the following procedure to remove the rotor (25 series only).
   
   • Clean all the surface areas and the threaded holes of contamination
     
   • Generously apply penetrating oil or the equivalent to the hub/rotor area
     
   • Insert (2) M10 x 1.5 bolts (jack screws) into the threaded holes of the rotor
     
   • Tighten both bolts evenly to force the rotor from the hub.
     

To install:

1. Clean all rust and contaminants from the both side of the rotor and the hub flange.
   NOTE If the rotor was removed using the jack screw method you must ensure that the hub flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before installing the rotor.
   
   
2. Install the rotor.
   
3. Install the caliper and the mounting bracket as an assembly.
   
4. Install the tire and wheel assembly.
   
5. Remove the safety stands.
   
6. Lower the vehicle.
   

REMOVAL & INSTALLATION Front Brakes

1. Raise and safely support the vehicle.
2. Remove the wheel and tire assembly.
3. Unfasten the disc brake caliper retaining bolts.
4. Remove the disc brake caliper and secure the caliper aside with mechanic's wire. Do not disconnect the brake hose.
5. Pull the brake rotor from the hub.
6. Inspect the rotor and refinish or replace, as necessary. If refinishing, the minimum thickness rotor thickness is stamped on the brake rotor.
7. To install:
   
8. Place the brake rotor to the hub. Make sure the mating surfaces are free of rust which may prevent the brake rotor from seating properly.
9. Remove the mechanic's wire and position the brake caliper.
10. Install the brake caliper retaining bolts to specification.
11. Install the wheel and tire assembly.
12. Lower the vehicle.
13. Pump the brake pedal several times to position the brake pads before moving the vehicle.
14. Road test the vehicle and check the brake system for proper operation.

It sounds like your hub/rotor is froze on....you'll need to apply some penetrant in the lug stud areas as wells as the area where the rotor mates to the axle hub.

1999 Taurus/Sable Section 06-03: Brakes, Front Disc 1999 Taurus/Sable Workshop Manual REMOVAL AND INSTALLATION Procedure revision date: 06/25/1998 Disc Removal

1. Raise vehicle on hoist.
   

1. Remove wheel and tire assembly. Be careful to avoid damage or interference with caliper bleeder screw fitting and front disc brake rotor shield (2K004).
   

1. CAUTION: Handle front disc brake rotor (1125) and disc brake caliper (2B120) assembly in such a way as to prevent deformation of front disc brake rotor , and nicking, scratching or contamination of brake linings/rotor surfaces.
   NOTE: To prevent damage, do not allow disc brake caliper to hang by the front brake hose (2078) .
   
   
   Remove caliper anchor plate bolts and discard. Position disc brake caliper out of the way. Prevent separation of caliper housing from anchor bracket because contamination of guide pin journals can occur.
   

1. NOTE: If excessive force must be used during front disc brake rotor removal, the front disc brake rotor should be checked for runout prior to installation.
   
   
   If additional force is required to remove front disc brake rotor , apply Rust Penetrant and Inhibitor F2AZ-19A501-A or equivalent meeting Ford specification ESR-M99C56-A on front and rear rotor/hub mating surfaces. First, strike front disc brake rotor between lug bolts (1107) with a plastic hammer. If this does not work, attach 2-3 Jaw Puller 205-D027 (D80L-1013-A) or equivalent and remove front disc brake rotor . Remove front disc brake rotor from wheel hub (1104) assembly by pulling it off the lug bolts.
   

Installation

1. If original front disc brake rotor is being installed, make sure rotor braking and mounting surfaces are clean.
   

1. CAUTION: Failure to clean rust and foreign material from rotor and hub mounting faces when installing new or old front disc brake rotors will result in high rotor runout, which will speed up the development of brake roughness shudder vibration.
   Apply a small amount of Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to pilot diameter of front disc brake rotor.
   

1. Install front disc brake rotor on wheel hub assembly.
   

1. Install disc brake caliper and new caliper anchor bracket bolts on front disc brake rotor . Tighten caliper anchor bracket bolts to 88-118 Nm (65-87 lb-ft).
   

1. CAUTION: Failure to tighten lug nuts (1012) in a star pattern may result in high rotor runout, which will speed up the development of brake roughness, shudder and vibration.
   Install wheel and tire assembly on vehicle. Tighten lug nuts to 115-142 Nm (85-104 lb-ft) using Rotunda Accutorq® Lug Nut Socket 164-R0303 or equivalent on a 1/2 inch air impact wrench, or use a torque wrench.
   

1. Lower vehicle.
   

1. Pump brake pedal prior to moving vehicle to position brake linings.
   

1. Road test vehicle.
   

here is procedure

Section 04-01: Suspension and Wheel Hubs, Front 1996 Taurus, Sable Workshop Manual
REMOVAL AND INSTALLATION Wheel Hub Bolt Removal

1. Raise vehicle on hoist.
   

1. Remove wheel and tire assembly. Refer to Section 04-04 .
   

1. Remove disc brake caliper (2B120), and front disc brake rotor (1125). Refer to Section 06-03 .
   

Brake Shoe and Lining Removal

1. Remove brake master cylinder filler cap (2162). Check fluid level in brake master cylinder reservoir (2K478). Remove brake fluid until brake master cylinder reservoir is half full. Discard removed fluid.
   

1. Raise vehicle on hoist. Refer to Section 00-02 .
   

1. Remove wheel and tire assembly from front disc brake rotor mounting face. Use care to avoid damage or interference with disc brake caliper (2B120), front disc brake rotor shield (2K004) or front wheel knuckle (3K185).
   

1. Remove rear brake pin retainers (2N386). ( I think it is a T 40 torx bit you need)
   

1. NOTE: It is not necessary to disconnect hydraulic connections.
   
   Lift disc brake caliper from front disc brake caliper anchor plate (2B292) and front disc brake rotor (1125). Do not pry directly against metal caliper piston or damage will occur.
   

1. Position disc brake caliper out of the way and support with wire to avoid damaging the disc brake caliper and front brake hose (2078).
   

1. Remove outer brake shoe and lining (2001) assembly from front disc brake caliper anchor plate.
   

1. Remove inner brake shoe and lining assembly.
   

1. Position lug bolt (1107) to clear front wheel knuckle (3K185).
   

1. Remove lug bolt from wheel hub (1104).
   
   
   
   

Installation

1. Install lug bolt into wheel hub.
   

1. Using a lug nut (1012), seat wheel hub bolt into wheel hub.
   

1. Install front disc brake rotor and disc brake caliper. Refer to Section 06-03 .
   

1. Install wheel and tire assembly. Tighten lug nut to 115-142Nm (85-104 lb-ft).
   

REAR WHEEL BEARING/ HUB

Removal Procedure

1. Raise the vehicle. Refer to Vehicle Lifting in General Diagnosis.
2. Remove the wheel and the tire. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment.
   1. Remove and support the brake caliper. Refer to Brake Caliper Replacement (Front) or Brake Caliper Replacement (Rear) in Brakes.
   2. Remove the brake rotor. Refer to Brake Rotor Replacement in Disc Brakes.
   3. Remove the ABS sensor wire connector.
   4. Remove the four bolts from the control arm.
   5. Remove the hub and bearing from the control arm.
   6. Remove the brake shield from the control arm.
   7. Clean the control arm face and the bore before installing the hub and the bearing.
   Installation Procedure
   
   Notice: Refer to Fastener Notice in Service Precautions.
   
   1. Install the brake shield and the hub and the bearing to the control arm with the four bolts. Be careful not to drop the hub and the bearing, as it could be damaged. Reconnect the ABS sensor. Tighten the hub and bearing bolts to 70 Nm (52 ft. lbs.).
   2. Install the brake rotor. Refer to Brake Rotor Replacement in Disc Brakes.
   3. Install the brake caliper. Refer to Brake Caliper Replacement (Front) or Brake Caliper Replacement (Rear) in Disc Brakes.
   4. Install the wheel and the tire. Refer to Tire and Wheel Removal and Installation in Wheels, Tires and Alignment. Tighten the wheel nuts to 140 Nm (100 ft. lbs.).
   5. Lower the vehicle.