Rotor Removal and Installation

REMOVAL
1. Raise and support vehicle.
2. Remove wheel and tire assembly.
3. Remove caliper.

NOTE: Do not allow brake hose to support caliper assembly.

Caliper Adapter:

4. Remove caliper adapter bolts from the steering knuckle and remove adapter.

Disc Brake Rotor:

5. Remove grease cap, cotter pin, nut lock, nut, washer and outer wheel bearing.
6. Remove the rotor from the spindle.

INSTALLATION
1. Inspect and repack wheel bearings if necessary. Install new grease seals if inner bearing was removed.
2. On models with all-wheel antilock system (ABS), check condition of tone wheel in rotor hub. If teeth on wheel are damaged, rotor and hub assembly will have to be replaced (tone wheel is not serviced separately).
3. Install rotor on spindle.
4. Install outer bearing, thrust washer and nut.
5. Tighten wheel bearing adjusting nut to 27 - 34 Nm (240 - 300 inch lbs.) while turning rotor.
6. Loosen wheel bearing adjusting nut completely. Then retighten nut finger tight. Wheel bearing end play should not exceed 0.076 mm (0.003 inch).
7. Install nut lock on bearing adjusting nut. Align lock slots with cotter pin hole and secure nut and lock with new cotter pin.
8. Clean grease cap and coat interior of cap with wheel bearing grease.
9. Install caliper adapter and tighten adapter bolts to:
- LD 1500: 176 Nm (130 ft. lbs.)
- HD 2500/3500: 285 Nm (210 ft. lbs.)
10. Install caliper and tighten bolts to 33 Nm (24 ft. lbs.).
11. Install wheel and tire assembly and lower vehicle.
12. Apply brakes several times to seat brake shoes. Be sure to obtain firm pedal before moving vehicle.