How do I replace the brake rotor on a 1991 Dodge Ram W150?

Answer 1

1991-1993 Dodge Ram W150 have tapered bearings in the hubs that must be removed to access the rotors. Jack the vehicle up and place on jack stands. Be sure the stands are level and positioned properly. Remove the wheels. You'll need a special spanner socket, that's a socket that looks like a tube with four lugs that will catch the four spaces on the nut. These sockets are available at parts stores like Auto Zone. Remove the brake caliper. There are two screws, one on top and one on the bottom of the caliper to remove. Remove the outer dust cap from the hub. Hammer and screw driver tapping at the edge of the caps will jar it loose. Once the cap has been removed, remove the external snap ring at the end of the axle. Remove the cog gear, large round gear with splines on the inside and outside. Use a coat hanger cut into two pieces. Bend the pieces of coat hanger so that a hook is formed and wiggle the gear out of the hub. It might be tight from the grease but will eventually wiggle loose. Slide the gear out. Lay the gear in a pan or other clean surface. Use the spanner socket to catch the outer nut and turn counter clockwise. With the outer nut removed, remove the spacer and then use the spanner socket again to remove the inner nut. Remove hub and rotor assembly from the spindle. Place the hub face up on some blocks of wood and hammer the wheel studs out of the hub. With wheel studs removed, hub will now easily separate from the rotor. Place new rotor on hub and drive studs back in. Reverse the above steps for installation but pay close attention when installing the lock nuts. The inner nut should be snugged up pretty tight, but do not over tighten and then back off just a bit. The inner nut has a pin that the washer must fit into. It may be necessary to loosen the inner nut and re-position so that the washer will fit flush against the inner nut. Install the outer nut and install the outer cog gear and snap ring.