Chrysler Full-Size Trucks 1989-1996 Repair Guide

Brake Disc (Rotor)


Brake pads may contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust from any brake surface! When cleaning brake surfaces, use a commercially available brake cleaning fluid.


  1. Raise and safely support the front of the truck with jackstands. Remove the front wheel.
  3. Remove the caliper assembly and support it to the frame with a piece of wire without disconnecting the brake fluid hose.
  5. Remove the hub and rotor assembly.
  7. Install the rotor in the reverse order of removal, and adjust the wheel bearing as outlined in Routine Maintenance .


See Figures 1, 2, 3 and 4

If the rotor is deeply scarred or has shallow cracks, it may be refinished on a disc brake rotor lathe. Also, if the lateral run-out exceeds 0.010 in. (0.25mm) within a 6 in. (152mm) radius when measured with a dial indicator, with the stylus 1 in. (25mm) in from the edge of the rotor, the rotor should be refinished or replaced.

A maximum of 0.020 in. (0.5mm) of material may be removed equally from each friction surface of the rotor. If the damage cannot be corrected when the rotor has been machined to the minimum thickness shown on the rotor, it should be replaced.

The finished braking surfaces of the rotor must be parallel within 0.007 in. (0.178mm) and lateral run-out must not be more than 0.003 in. (0.076mm) on the inboard surface in a 5 in. (127mm) radius.

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Fig. Fig. 1: Use a dial indicator and micrometer to check the rotor for run-out and thickness

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Fig. Fig. 2: A correct final rotor finish

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Fig. Fig. 3: Location of the rotor minimum thickness marking

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Fig. Fig. 4: Exploded view of a rotor mounting to the hub-4WD Dakota models shown