How do you remove the front disk brake rotor off of a 1993 Toyota 4X4 truck?

Answer 1

Toyota made it relatively complicated to get to the rotor. It is is not difficult, but it involves disassembly of a few components. First, remove the wheel. Second, remove the 4WD locking hub cover (Manual) or ADD (automatic) assembly. The paper gasket can be re-used if you are careful in your disassembly. Third, remove the 4WD hub body; this is the large shiny metal star-shaped housing. Loosen the nuts most of the way, but do not remove them from the studs. Underneath the nuts are cone washers. There are several ways to loosen the cone washers. My favorite is to simply hit the housing with a rubber mallet or dead-blow hammer. This pops the washers loose. That is why I leave the nuts on - to keep the washers from flying off the studs. Fourth, remove the hub. This entails removing the outer bolt (it bolts into the half-shaft. After the bolt is off, there is a washer, a large nut, a large lock washer and another large nut. Removing all of these exposes the outer bearing and allws the hub/rotor assembly to be pulled off the knuckle. Don't drop the bearing! Fifith, unbolt the rotor from the hub. You might have to coerce the rotor quite a bit (with a hammer or press), but the rotor will come off. To replace the rotor, work in reverse. There are some important torque specs that should be followed during re-assembly; consult the dealer or a repair manual for the specs. While you're in there, consider re-packing the wheel bearings.