REMOVAL & INSTALLATION
See Figures 1 through 7
- Raise and support the front end on jackstands.
- Remove the wheel.
- Remove the caliper assembly as described earlier in this section.
- For 4-wheel drive models, follow the procedure given under hub and wheel bearing removal in Drive Train for models with manual and automatic locking hubs.
For 2-wheel drive vans:
- Remove the grease cup from the hub.
- Remove the cotter pin, castellated retainer, adjusting nut and flat washer from the spindle.
- Remove the outer bearing cone and roller assembly.
- Pull the hub and rotor assembly off the spindle.
New rotor assemblies come protected with an anti-rust coating which should be removed with denatured alcohol or degreaser. New hubs must be packed with EP wheel bearing grease. If the old rotors are to be reused, check them for cracks, grooves or waviness. Rotors that aren't too badly scored or grooved can be resurfaced by most automotive shops. Minimum rotor thickness should be stamped on the rotor. If refinishing exceeds that, the rotor will have to be replaced.
For rear wheel drive models, perform the following steps:
- Install the hub and rotor assembly on the spindle. Keep the hub centered on the spindle to prevent damage to the retainer and the spindle threads.
- Install the outer bearing cone and roller assembly and the flat washer on the spindle, then install the adjusting nut finger tight. Adjust the wheel bearing(s) as described in Suspension & Steering .
- For all wheel drive vehicles, refer to the front hub procedure located in Drive Train .
- Install the caliper to the spindle as described in Suspension & Steering .
- Install the front tire(s), then lower the van and tighten the lugnuts to 85-115 ft. lbs. (115-155 Nm). Install the wheel cover.
- Before moving the van, pump the brake pedal several times to restore normal brake travel.
See Figure 8
The brake rotor should be checked for scratches, scoring and cracks. If any cracks, or excessive scoring and scratches are found, the rotor must be replaced with a new one.
Smaller scratches and scoring will be removed when the rotor is refinished.
Check the rotor for runout as follows:
- First eliminate the wheel bearing end-play by tightening the adjusting nut to specifications. Check to ensure that the front disc brake rotor can still be rotated,
- Clamp a dial indicator to the spindle knuckle assembly so that the stylus contacts the rotor approximately 1 in. (25.4mm) from the outer edge.
- Rotate the rotor one turn (360°) and take an indicator reading. If the reading exceeds 0.003 in. (0.08mm) total lateral runout, replace or resurface the front disc brake rotor.
The rotor should be refinished to remove scoring, out-of-round, and runout. Use a disc brake lathe to resurface the rotors.
The minimum overall thickness specifications shown on the rotor allows for a 0.030 in. (0.8mm) machining cut plus 0.030 in. (0.8mm) for additional wear. If the thickness falls below the minimum, the rotor must be replaced.