Astro, Safari 1997-2005

Brake Disc (Rotor)

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Removal & Installation



The 2-wheel drive brake disc rotor and the wheel bearing hub assembly are designed as one piece; therefore, to remove the brake disc, remove the wheel bearing assembly.

The 4-wheel drive brake disc rotor is separate from the hub assembly and can be removed without removing the hub and bearings assembly. The hub and bearing assembly is non-serviceable and has to be replaced as a unit.

2-Wheel Drive

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.

  1. Raise and safely support the vehicle.
  2.  
  3. Remove the tire and wheel assembly.
  4.  
  5. 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; instead wire the caliper out of the way with the line still connected.
    NOTE
    Once the rotor is removed from the vehicle the wheel bearings may be cleaned and repacked or the bearings and races may be replaced.

  6.  
  7. Carefully pry out the grease cap, then remove the cotter pin, spindle nut, and washer. Remove the hub, being careful not to drop the outer wheel bearings. As the hub is pulled forward, the outer wheel bearings will often fall forward and they may easily be removed at this time.

    Click image to see an enlarged view

    Fig. Exploded view of brake assembly-2WD models

  8.  

To install:

  1. Carefully install the wheel hub over the spindle.
  2.  
  3. Using your hands, firmly press the outer bearing into the hub.
  4.  
  5. Loosely install the spindle washer and nut, but do not install the cotter pin or dust cap at this time.
  6.  
  7. Install the brake caliper.
  8.  
  9. Install the tire and wheel assembly.
  10.  
  11. Properly adjust the wheel bearings:
    1. Spin the wheel forward by hand and tighten the nut to 12 ft. lbs. (16 Nm) in order to fully seat the bearings and remove any burrs from the threads.
    2.  
    3. Back off the nut until it is just loose, then finger-tighten the nut.
    4.  
    5. Loosen the nut 1 / 4 - 1 / 2 turn until either hole in the spindle lines up with a slot in the nut, then install a new cotter pin. This may appear to be too loose, but it is the correct adjustment.
    6.  
    7. Proper adjustment creates 0.001-0.005 in. (0.025-0.127mm) end-play.
    8.  

  12.  
  13. Install the dust cap.
  14.  
  15. Install the wheel/hub cover, then remove the supports and carefully lower the vehicle.
  16.  

4-Wheel Drive

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.

  1. Raise and safely support the vehicle.
  2.  
  3. Remove the tire and wheel assembly.
  4.  
  5. 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; instead wire the caliper out of the way with the line still connected.
  6.  
  7. If equipped, remove the lockwashers from the hub studs in order to free the rotor.
  8.  
  9. Remove the brake disc (rotor) from the wheel hub.
  10.  
  11. Inspect the disc for nicks, scores and/or damage, then replace if necessary.
  12.  
  13. Installation is the reverse of the removal. DO NOT attempt to move the vehicle unless a firm brake pedal is felt.

    Click image to see an enlarged view

    Fig. Rotor, hub and bearing assembly-All wheel drive

  14.  

 
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