Removal & Installation
- Remove 2 / 3 of the brake fluid from the master cylinder.
- Raise and support the vehicle.
- Remove the tire and wheel assembly.
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
- Mark the relationship of the rotor to the hub.
- Remove the caliper and mounting bracket as an assembly.
- Hang the caliper and the mounting bracket assembly from the suspension using mechanics wire.
If equipped with dual rear wheels, remove the hub extension.
- Remove the rotor. Remove the rotor screw first, if equipped.
- If the rotor is difficult to remove due to corrosion in the hub area use the following procedure to remove the rotor (2500 series only).
Clean all rust and contaminants from the both side of the rotor and the hub flange.
NOTEIf 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.
- Install the rotor.
- Clean the threads of the bolts with brake parts cleaner or the equivalent and allow to dry.
- Install the caliper and the mounting bracket as an assembly. Apply Red Loctite® #272 to the threads of the bolt. On 2005-06 models and 2007 Classic, tighten the bolts to 133 ft. lbs. (180 Nm) on 6 bolt hubs and 221 ft. lbs. (300 Nm) on 8 bolt hubs. On 2007 models except Classic, tighten them to 129 ft. lbs. (175 Nm) on 6 bolt hubs and 221 ft. lbs. (300 Nm) on 8 bolt hubs.
- Install the hub extension on dual rear wheel models. Tighten the bolts to 96 ft. lbs. (130 Nm).
- Install the tire and wheel assembly.
- Remove the safety stands.
- Lower the vehicle.