Brake Rotor/Disc: Service and Repair

WHEEL HUB/ROTOR ASSEMBLY

Remove or Disconnect

Figure 44 V-Model Front Suspension:

Figure 45 - V-Model Front Suspension:

Figure 48 - Removing/Installing Locking Or Adjusting Nut:

Figure 49 - Knuckle And Hub/Rotor Components (V10/1500 And V20/2500 Models):

Figure 50 - Knuckle And Hub/Rotor Components (V30/3500 Models):

Figure 51 - Knuckle And Hub/Rotor Components (V30/3500):

Tools Required:

- J 6893-D Wheel Bearing Nut Wrench (V10/1500-20/2500 Models)
- J 23446 Torque Wrench Adapter
- J 26878-A Wheel Bearing Nut Wrench (V30/3500 Models)

- Raise the vehicle and support it with suitable safety stands.
1. Wheel and tire assembly.
2. Caliper. Brake Caliper
3. Locking hub assembly. Differential Assembly
4. Lock nut (250), ring (251) and adjusting nut (252).
- Use J 6893-D for V-10/1500-20/2500 models (figure 48).
- Use J 26878-A for V30/3500 models (figure 48).
5. Hub/rotor assembly (257).
- Outer wheel bearing (253) will slide off the spindle (265) ahead of the hub/rotor (257).
- Use a brass drift and hammer for seal (260) and races (254 and 258).
- The inner bearing (259) and race (258) are behind the seal (260).

Inspect

1. Rotor braking surfaces for scoring, pitting or cracks.
Repair or replace as necessary.
2. Wheel bearing (253 and 259) and races (254 and 258).
- If either a bearing or its race is damaged or worn, replace both.

Install or Connect

Figure 44 V-Model Front Suspension:

Figure 45 - V-Model Front Suspension:

Figure 49 - Knuckle And Hub/Rotor Components (V10/1500 And V20/2500 Models):

Figure 50 - Knuckle And Hub/Rotor Components (V30/3500 Models):

Figure 51 - Knuckle And Hub/Rotor Components (V30/3500):

Figure 52 - Installing The Outer Wheel Bearing Race:

Figure 53 - Installing The Inner Bearing Race:

Tools Required:

- J 8092 Driver Handle
- J 6368 Bearing Race Installer (Outer)
- J 23448 Bearing Race Installer (Inner)
- J 6893-D Wheel Bearing Nut Wrench (V10/1500-20/2500 models)
- J 26878-A Wheel Bearing Nut Wrench (V30/3500 models)
- J 23446Torque Wrench Adapter

1. Races (254 and 258) into the hub/rotor (257).
- Use J 8092 and J 6368 for installation of the outer bearing outer race (254) (figure 52).
- Use J8092 and J 23448 for installation of inner bearing outer race (258) (figure 53).
- Do not damage the hub/rotor during the race installations.

Clean

- Grease from the rotor/hub (257) and spindle (265).
- Grease from the wheel bearings (253 and 259).
- Use clean solvent and a small brush with no loose bristles.
- Do not spin the wheel bearings with compressed air to dry them - the wheel bearings may be damaged.

Important:

- Use an approved high-temperature front wheel bearing grease.
- Do not mix greases as mixing may change the grease's properties resulting in poor performance.

2. Apply a thin film of grease to the spindle at the outer wheel bearing seat and at the inner wheel bearing seat, shoulder and seal seat.
3. Put a small quantity of grease inboard of each wheel bearing cup, inside the rotor/hub (257).
4. Fill the wheel bearing (cone and roller assemblies) full of grease.
- Use a cone-type grease packer that forces grease into the bearing.
- If a cone-type grease packer is not available, pack the wheel bearings by hand.
- If packing the wheel bearings by hand, work the grease into the bearings between the rollers, cones, and the cage.

Notice: Failure to completely pack the wheel bearings (cones, rollers, and cage) with grease will result in premature wheel bearing damage and/or wear.

5. Inner wheel bearing (259) into the rotor/hub (257).
- Put an additional quantity of grease outboard of the wheel bearing.
6. New seal (260).
- Use a flat plate to install the seal so it is flush with the rotor/hub flange.
- Lubricate the seal lip with a thin layer of grease.
7. Rotor/hub (257).
- Do not damage the spindle threads.
8. Outer wheel bearing (253).
- Press on the spindle until the wheel bearing fully seats against the rotor/hub outer race.
9. Adjusting nut (252).
- Adjust the wheel bearing.

Notice: All front suspension fasteners are important attaching parts in that they could affect the performance of vital parts and systems, and/or could result in major repair expense. They must be replaced with one of the same part number or with an equivalent part if replacement becomes necessary. Do not use a replacement part of lesser quality or substitute design. Torque values must be used as specified during reassembly to assure proper retention of these parts.

10. Ring (251) and locking nut (250).
- Tang on the inside diameter of the ring must pass onto the slot on the spindle.
- The hole in the ring must align with the pin on the lock nut (250). Move the adjustment nut (252) to align the pin.
- Use J 6893-D or J 26878-A

Tighten
- Lock nut (250) to 217 Nm (160 ft. lbs.) minimum.

11. Locking hub assembly (249). Differential Assembly
12. Caliper. Brake Caliper
13. Wheel and tire assembly.
- Lower the vehicle.