Brake rotor removal - Sierra GMC Cars & Trucks

1. Raise and support the vehicle; Remove the wheel and tire assembly;
2. After removing the tire, remove the brake pads;
3. Remove the disc brake caliper by removing the two disc brake caliper pin bolts. Lift the disc brake caliper from the disc brake caliper anchor plate (2B292). If necessary, remove the V-springs.
4. Remove the pads. Remove the front disc brake caliper anchor plate stainless steel rail clips.
5. Remove the rotor.
6. Note: Perform this step for DRW vehicles. Remove the eight hub extender nuts, the hub plate and the rotor. Remove the eight hub plate nuts. Remove the hub plate. Remove the rotor.

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Front brake
Step 1: Identify Front Disc Brake Components

Front Wheel Drive Brake Assembly
Most front disc brake components include: brake rotor, brake pads, brake caliper, caliper mount and brake flex hose. Brake service usual occurs between 20,000 and 40,000 miles depending on driver habits, road conditions and brake pad/ rotor materials used.
Step 2: Remove Brake Caliper to Replace Pads

Removing Brake Caliper Mounting Bolts
Locate primary caliper mounting bolts; apply wrench pressure counter-clockwise (When looking at the head of the bolt) to remove the bolts, upper and lower. Make sure the bolt threads are in good shape and replace if necessary.
Step 3: Remove Front Brake Caliper

Remove Front Brake Caliper
After removing the primary caliper mounting bolts lift the brake caliper off of the rotor and then tie or secure to the side, being careful not to bend or kink the brake caliper flex hose. Thoroughly inspect brake caliper and brake hoses for leakage, cracks or chaffing and replace as needed. Next remove the brake pads (If not mounted in the caliper) and secondary caliper mounting bolts. Notice how great protective gloves work, most technicians use them on the job today.
Step 4: Remove Brake Pads

Remove Front Brake Pads
Once the brake pads have been removed, make sure if there is anti rattle hardware to transfer to the new brake pads. Some brake pad manufacturers will include the proper lube (Caliper slides) and anti-rattle hardware to ensure proper performance of their product.
Step 5: Remove Caliper Mount

Remove Caliper Mount Bracket
Finish removing secondary caliper mount bolts and remove caliper mount. Note: clean and lube caliper slides and pad friction surfaces of all foreign material or build-up.
Step 6: Remove Brake Rotor

Remove Brake Rotor
With the caliper mount out of the way you can now remove the brake rotor. Sometimes it can get stuck so you may need to tap it with a hammer or use penetrating oil to free it up. Some manufacturers use small screws to hold the rotor on as well. Clean and inspect wheel studs, replace if any are damaged. Also clean bearing hub rotor mount surface to ensure the proper mounting of the new brake rotor. Inspect the ABS sensor wheel for cracks or damage and replace as needed.
Step 7: Depressing the Brake Caliper

Resetting Brake Caliper
To install the new brake pads you must retract the brake caliper piston. Remove the master cylinder lid or open the brake caliper bleeder screw to allow excess brake fluid to be released if necessary. Install C clamp tool and gently tighten clamp until caliper piston is fully depressed. Note: use old brake pad to protect the caliper piston. Close the bleeders once the piston is retracted completely
Step 8: Installing New Brake Rotor

Install Brake Rotor
Install new brake rotor, the new rotor is manufactured with a protective film over the rotor to keep it from rusting, remove protective film with brake cleaner before installing; also after the brake job is complete you may experience a small amount of smoke from the rotor when first used. This is normal and will go away after the first couple of uses.
Step 9: Installing New Front Brake Pads

Installing New Brake Pads
Reinstall the front brake caliper mount, and then install front brake pads. Make sure the pads are seated properly in the caliper mount; it must be a close fit to work properly..
Step 10: Reinstall Front Brake Caliper

Re-Install front Bake Caliper
Reinstall front brake caliper and reinstall caliper-mounting bolts, recheck all mounts and mounting bolts. Check the caliper slides to be sure there is no bind and that the caliper moves freely back and forth on the caliper slides. Bleed brake system per manufacturer's specifications to relieve any air trapped in the system. Before driving the vehicle, push the brake pedal down and let it up slowly, repeat until normal brake pedal operation resumes, this operation is forcing the brake pads to travel to the brake rotors.

PATH: Brakes > Front Disc Brakes > Brake Disc (Rotor) > Removal & Installation Removal & Installation

1. Raise and support the front of the vehicle on jackstands. Remove the front wheels.
   
2. Remove the caliper assembly; do not let the caliper assembly hang by the brake hose, instead support it with a piece of wire looped around the front spring or control arm.
   
3. Remove the retaining screw from the brake rotor and remove the rotor from the hub.
   

An impact driver, No. 3 phillips screwdriver bit, and a hammer may be needed to remove the retaining screw. It is fairly easy to destroy the screw slots using an ordinary phillips screwdriver to remove the tightly driven screw (see photo).

1. To install the disc, replace the disc on the hub, screw in the retaining screw and replace the caliper assembly.
   

PATH: Brakes > Rear Disc Brakes > Brake Disc (Rotor) > Removal & Installation Removal & Installation

1. Raise and safely support the vehicle.
   
2. Remove the wheel and tire assembly.
   
3. Disconnect the caliper from the caliper bracket. Support the caliper out of the way with a length of wire. Do not allow the caliper to hang from the brake hose.
   
4. Remove the caliper bracket.
   
5. Remove the two 6mm screws and the brake disc. If the brake disc is difficult to remove, install two 8mm bolts into the threaded holes and tighten them evenly to prevent cocking the rotor.
   
6. Install the rotor in position. Install the two 6mm retaining screws.
   
7. Install the brake caliper. Install the tire and wheel assembly.
   

PATH: Brakes > Rear Disc Brakes > Brake Disc (Rotor) > Removal & Installation Removal & Installation

1. Raise and safely support the vehicle.
   
2. Remove the wheel and tire assembly.
   
3. Disconnect the caliper from the caliper bracket. Support the caliper out of the way with a length of wire. Do not allow the caliper to hang from the brake hose.
   
4. Remove the caliper bracket.
   
5. Remove the two 6mm screws and the brake disc. If the brake disc is difficult to remove, install two 8mm bolts into the threaded holes and tighten them evenly to prevent cocking the rotor.
   
6. Install the rotor in position. Install the two 6mm retaining screws.
   
7. Install the brake caliper. Install the tire and wheel assembly.
   
8. 
   

How to replace the rear brake pads on a 1995 through 2001 Ford Explorer The system utilizes a drum-in-hat type rear brake rotor. The integral drum allows the use of a drum-and-shoe type parking brake system. All other components are similar to their front disc brake components Remove the two bolts on either side of the brake hose with the rubber boots. Do not remove the four bolts where the axle ties in. The two bolts to be removed require a 10mm socket/wrench. Loosen the pads from the caliper Rotor Removal In order to take the rotors off (replace with new or have them machined), it is best to loosen the emergency brake shoes. To do this, behind the rotors, in the back there is a rubber plug, remove that and you can use a screw driver to engage the teeth of the adjusting screw, turn it clockwise to loosen, usually 10-20 teeth. Usually this means turn it downward. After this, it may still be difficult to get the rotors off without tapping them. Use a rubber mallet and hit them from behind. Before really whacking the rotor, make sure you have loosened the adjusting screw enough. It may take heavy swings of the rubber hammer to do this. It will eventually break loose. Parking Brake You might want to check the parking brake while you are here. To remove:

• Remove the rear disc brake rotor.

• Remove the outboard return spring.

• Remove the adjusting screw spring.

• Remove the rear brake shoe hold-down spring and pin.

• Remove the brake shoe adjusting screw and nut.

• Remove the front brake shoe hold-down spring and pin.

• Remove both parking brake shoes and the inboard return spring.

• Check the parking brake lever for excessive wear and replace as necessary.

To install:

• Position the front parking brake shoe to the backing plate and install the hold-down pin and spring.

• Install the rear parking brake shoe with the inboard return spring.

• Position the brake shoe adjuster screw and nut on the shoes and install the rear shoe hold-down pin and spring.

• Install the brake shoe adjuster spring.

• Install the outboard return spring.

• Adjust the parking brake shoes and install the rotor, caliper and wheel.

• Lower the vehicle and tighten the wheel lug nuts to 100 ft. lbs. (135 Nm).

ADJUSTMENT

• Measure the inside of the drum portion of the rear brake rotor

• Remove the rear disc brake rotor.

• Using Brake Adjustment Gauge D81L-1103-A or equivalent, measure the inside diameter of the drum portion of the rear disc brake rotor.

• Subtract 0.020 in. (0.508mm) from the first measurement, adjust the brake shoes to that size

• Adjust the parking brake adjuster screw until the outside diameter of the parking brake shoes measures 0.020 in. (0.508mm) less than the drum measurement.

• Install the rear disc brake rotor.

Reassembly Reassembly is easy. Put new or machined rotors back on by sliding them over the lugs (they should slide on easily.) Loosen bleeder valve (having a catch bottle handy is good). Push calipers in slowly (using a c-clamp or large channel lock pliers), close bleeder valve. Put on pads. Lubricate metal clips with small amount of anti-seize. Re-adjust the emergency brake by turning the opposite direction from loosening. Refill the brake master cylinder

To remove the brake rotor, you must first remove the brake pads and caliper. There are two bolts that hold the brake caliper in place. Remove the two bolts and tie the caliper up out of the way. Be careful not to break the brake line connected to the back of caliper. Once the caliper is removed, simply slide the rotor off. To install a new rotor, simply slide rotor over studs and replace the caliper with new brake pads. It is as simple as that.

Removal & Installation CAUTION Dust and dirt accumulating on brake parts during normal use may contain asbestos fibers from production or aftermarket brake linings. Breathing excessive concentrations of asbestos fibers can cause serious bodily harm. Exercise care when servicing brake parts. Do not sand or grind brake lining unless equipment used is designed to contain the dust residue. Do not clean brake parts with compressed air or by dry brushing. Cleaning should be done by dampening the brake components with a fine mist of water, then wiping the brake components clean with a dampened cloth. Dispose of cloth and all residue containing asbestos fibers in an impermeable container with the appropriate label. Follow practices prescribed by the Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) for the handling, processing, and disposing of dust or debris that may contain asbestos fibers.

The brake rotor can be removed without separating the caliper from the mounting bracket.

1. Release the parking brake.
   
2. Remove 2/3 of the brake fluid from the master cylinder.
   
3. Raise and support the vehicle.
   
4. Remove the tire and wheel assembly.
   
5. Remove the caliper and mounting bracket as an assembly.
   
6. Hang the caliper and mounting bracket assembly from the suspension using mechanics wire.
   
7. Remove the rotor. Slowly turn the rotor while pulling the rotor away from the axle. (15 series).
   
8. Remove the rotor. Slowly turn the rotor while pulling the rotor away from the axle. (25 series).
   NOTE If the rotor is stuck to the hub, try using a slide hammer to free it.
   
   

To install:
WARNING Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral run-out (LRO) of the brake rotor, which could lead to brake pulsation.

1. Thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange.
   
2. Thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor.
   
3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining.
   
4. Install the rotor. Slowly turn the rotor while pushing the rotor towards the axle. (15 series).
   
5. Install the rotor. Slowly turn the rotor while pushing the rotor towards the axle. (25 series).
   
6. Install the caliper and the mounting bracket as an assembly.
   
7. Install the tire and wheel assembly.
   
8. Lower the vehicle.
   

Removal & Installation


After removing the caliper body, unfasten the retaining bolts and remove the caliper mounting bracket, in order to remove the rotor

1. Use a siphon or clean turkey baster to remove about half of the brake fluid from the master cylinder.
   
2. Raise and safely support the vehicle and remove the tire/wheel assembly.
   
3. Remove the caliper mounting bolts, then lift the caliper assembly away from the brake rotor.
   
4. Use a suitable piece of wire to suspend the caliper assembly. This will prevent the weight of the caliper from being supported by the brake flex hose which will damage the hose.
   
5. Once the caliper body and brake pads are removed, unfasten the caliper bracket mounting bolts, then remove the bracket from the rotor.
   
6. Remove the rotor retaining screws.
   
7. Remove the brake rotor by pulling it straight off the wheel mounting studs or if seized in place, remove the stubborn brake rotor by threading in two 8 x 1.25mm bolts, two turns at a time until the brake rotor is released.
   

To install:

1. If necessary, completely retract the piston into the caliper using a large C-clamp or other suitable tool as provided in the front disc brake pad replacement procedures in this section.
   
2. Install the brake rotor onto the wheel hub and tighten the mounting screws.
   
3. Install the caliper mounting bracket and secure with the retaining bolts.
   
4. Install the caliper and pad assembly over the brake rotor and mounting bracket and install the mounting bolts.
   
5. Fill the master cylinder to the proper level with fresh brake fluid.
   
6. Install the tire/wheel assembly and lower the vehicle.
   
7. Pump the brake pedal until the brake pads are seated and a firm pedal is achieved before attempting to move the vehicle.
   

CAUTION Do not move the vehicle until a firm pedal is obtained.

1. Road test the vehicle to check for proper brake operation.
   

Remove tyres. Remove brake pads.
Remove Brake calipers bolts from the back of calipers.
Put calipers aside without removing brake lines. Remove rotor bolts. Remove rotors. Install new rotors Make sure new rotors are clean from any grease that comes on it with petrol or any cleaning chemical for that purpose (no water) Install calipers Install new brake pads Good luck

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.