How do you remove a brake rotor on a 1994 ford bronco 4x4?

Answer 1

Easy to do but takes time and you need to pay attention to what order you remove the items. Jack up the Bronco and support with jack stand on the side you are working on. It does not make sense to do both sides at the same time as that is a ton of weight just hanging up there. I prefer having 3 wheels on the ground. My 96 bronco has manual locking hubs.

1) Take off chrome cap with a small torc. They are not that tight.

2) remove 1st retention clip. This can be done with 1 (2 is better) small tip screwdriver. Then remove the large retainer clip that is circling the inside lip of the hub itself, keeping the lockable gear assembly in place. Again just use a screwdriver.

3) this should allow the entire inner and outer locking gears to basically 'spring' out as they are being pushed by the spring behind it. There is another easy retaining clip that keep the inner gear inside the outer gear but you don't have to remove this clip as the inner and out gear come out as 1 piece. Take the large spring out also obviously.

4) You will see an odd large nut with 4 notches on it. This looks like a special socket is needed but it is not. All you need is a large flat screwdriver and a hammer to gently tap "counter clockwise" as this nut is not torqued down very tight (and will not be when you put back on either).

5) take off the large washer with all the little holes in it. Remove it with a little angled pick of some sort as it just needs some help getting it all the way out of the hub. Notice the notch out lip on it as it only slides back on at a particular angle.

6) take off the next large nut the same way with a screwdriver, small pry bar etc. Remember counter clockwise. Notice the little 'nipple' of metal pointing towards you. This nipple actually goes through one of the holes in the washer you just took off (when re assembling). This is why I say pay attention to these small details as they matter.

7) now take out the outer bearing and repack with grease. Use the grease in the palm of your hand trick and just keep scooping and rotating until grease squeezes up and out of the race.

8)remove the hub.

9) now drive all 5 studs out by putting one lug nut on hand tight and tap it down with a hammer. To reverse you might want to use a large nut that fits loosely over each stud and air impact all 5 back on using 1 lug nut over your large nut as a spacer basically. I tried to just hammer them back in from the other side using a 3/4 extension and just could not do it all the way. The rotor was loose a bit so the impact gun idea worked best for me, or maybe just needed a bigger hammer!

10) The abs or speed sensor ring or whatever it is just taps off with a screwdriver and hammer and taps right back on.

11) to get the hub to fall out of the rotor I just hammered lightly on the outside of the back bearing race. It did not dent too bad and the hub just fell out.

12) repack the rear bearing after removing the seal. I even reused the seal as there was no grease leaking from it so what the heck.

13) put it all back together in reverse. Just don't hammer too tightly the 2 large nuts, just one or two light taps so the hub assembly is snug. Don't forget to line up the metal nipple on the inner nut with any hole in the washer that goes between the 2 large nuts.