Tracker 2000-2004

Brake Disc (Rotor)

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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.

  1. Remove two-thirds of the brake fluid from the master cylinder reservoir using a siphon (or equivalent).
  2.  
  3. Raise and safely support the front of the vehicle securely on jackstands.
  4.  
  5. Remove the tire and wheel assembly.
  6.  
  7. Position the C-clamp around the outer pad and caliper. Tighten the clamp until the piston bottoms in its bore.
  8.  
  9. Remove the 2 mounting bolts, the caliper, and the caliper bracket.
  10.  
  11. Lift the caliper and the caliper bracket, along with the brake pads, off of the rotor.
  12.  
  13. Suspend the caliper and the caliper bracket with a wire in order to prevent damage to the brake hose. Do not allow the brake components to hang from the flexible brake hoses. Damage to the brake hoses could result.
  14.  
  15. Inspect the brake rotor for thickness variation. The maximum rotor thickness variation is 0.013 mm (0.0005 in).
  16.  
  17. Inspect the brake rotor for lateral runout. The maximum rotor lateral runout is 0.15 mm (0.006 in).
  18.  
  19. Inspect the brake rotor surface. Maximum scoring depth (rotor surface finish depth) is 0.38 mm (0.015 in).
  20.  
  21. Remove the brake rotor from the wheel hub. If necessary, install two 8 mm bolts into the rotor. Tighten the bolts in order to force the rotor off of the wheel hub.
  22.  

To install:

  1. Install the brake rotor to the hub.
  2.  
  3. Place the caliper and the caliper bracket into position. Secure the caliper and the caliper bracket with the 2 caliper bracket mounting bolts and tighten to 61.5 ft. lbs. (85 Nm).
  4.  
  5. Install the tire and wheel assembly.
  6.  
  7. Lower the vehicle.
  8.  
  9. Fill the master cylinder reservoir.
  10.  
  11. Start the engine.
  12.  
  13. Press the brake pedal several times in order to position the caliper piston.
  14.  

 
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