QuestionHow do I remove the rotors from my 1996 Dodge Ram 2500?
AnswerDISC BRAKE ROTOR (WITH TAPERED BEARINGS)
REMOVAL
Raise vehicle.
Remove wheel and tire assembly.
Remove caliper from rotor.
On models with removable adapter hub, remove hub from rotor.
On models with one-piece rotor and hub assembly, remove grease cap that covers cotter pin and hub nut.
Remove grease cap from hub. On models with long adapter, use long pry tool with angled end to remove grease cap. Pry against flats at each side of cap to loosen and remove it.
Remove cotter pin from spindle and wheel bearing adjusting nut Rotor And Hub Assembly (With Tapered Bearings)
Remove locknut from wheel bearing adjusting nut. Then remove thrust washer and outer wheel bearing.
Remove rotor and hub assembly from spindle.
Inspect wheel bearings and interior of hub. If bearings need repacking, remove grease seal and inner wheel bearing from rotor hub.
INSTALLATION
Repack wheel bearings with Mopar high temperature bearing grease. Apply grease to bearing races as well. Then install inner bearing in hub and install new grease seal.
Apply liberal coat of bearing grease to spindle, interior of rotor hub, grease seal lip and seal surface of spindle.
Install rotor and hub assembly on spindle.
Install outer wheel bearing thrust washer and bearing adjusting nut. Tighten nut only enough to remove end play at this time.
Install disc brake caliper. Do not seat caliper pistons at this time. Pistons must not be seated until after wheel bearing adjustment has been completed.
On models with removable hub adapter install adapter on rotor.
Install wheel and tire assembly. Tighten wheel nuts snug but not to final torque at this time.
Adjust wheel bearings by rotate wheel and fully tighten bearing adjusting nut to seat bearings. Loosen and tighten bearing adjusting nut once again while rotating wheel.
Continue rotating wheel and back off adjusting nut until wheel end play is no more than 0.025 to 0.051 mm (0.001 to 0.002 in.)
Install nut lock on adjusting nut and install new cotter pin. Adjusting nut can be tightened slightly to align cotter pin holes if necessary. Verify that wheel bearing adjustment is still OK.
Install grease cap and wheel cover/hub cap.
Tighten lug nuts to proper torque.
DISC BRAKE ROTOR (WITH UNIT BEARINGS)
REMOVAL
Raise vehicle.
Remove wheel and tire assembly.
Remove caliper from rotor.
On 1500 model vehicles remove rotor.
On models with removable adapter hub, remove hub from rotor.
Remove cotter pin from rotor hub nut and remove nut Hub Nut Cotter Pin
Remove bolts that secure rotor and hub to steering knuckle from inboard (back) side of steering knuckle Rotor And Hub Attaching Bolts
Remove rotor and hub assembly Rotor Hub And Unit Wheel Bearing Assembly Replace bearing assembly if damaged.
Remove hub spacer from steering knuckle Hub Spacer Note spacer position for installation reference.
INSTALLATION
Apply liberal quantity of Mopar, or Permatex anti-seize compound to splines of front drive shaft Hub Spacer Positioning
Replace grease seal in steering knuckle if damaged.
Insert two rearmost, top and bottom rotor hub bolts in steering knuckle. Insert bolts through back side of knuckle so they extend out front face as shown.
Position hub spacer on bolts just installed in knuckle. Be sure flat on spacer is positioned toward rear. Use chassis grease to hold spacer in place on knuckle.
Apply 1-2 drops of Mopar Lock N' Seal, or Loctite 242 to threads of rotor and hub retaining bolts.
Align rotor hub with drive shaft. Then start shaft into rotor hub splines.
Align bolt holes in unit bearing flange with bolts previously installed in knuckle. Then thread bolts into bearing flange far enough to hold assembly in place.
Install remaining rotor retaining bolts. Tighten all bolts securely
Install washer and hub nut. Tighten nut securely.
Install new cotter pin in hub nut. Tighten nut as needed to align cotter pin hole in shaft with opening in nut.
Install disc brake caliper.
Install wheel and tire assemblies and lower vehicle.
Apply brakes several times to reseat brakeshoes and caliper piston. Do not move vehicle until firm brake pedal is obtained.
