How to Change the Rotors on a 1996 F150

Ford F150 brake rotors on the 1996 models mount the wheel to the vehicle and provide the friction surface for the brake pads to bear on. The rotor is mounted on a spindle with a pair of tapered roller wheel bearings to support the radial and lateral loads of driving. Brake rotors help to dissipate the heat generated by the brake friction and must maintain a machined, flat surface to maximize their braking power. Malfunctioning brake calipers can overheat the rotor and cause it to warp, and worn brake pads can grind away rotor material and ruin the finish on the rotor, making replacement of the rotor a necessity. To change the rotors on either side of the vehicle, use the same procedure.

Instructions

Remove the hubcap with the narrow end of the tire tool by inserting the tip of the tool behind the edge of the hubcap and then prying the hubcap off. Loosen the lug nuts a half-turn with the tire tool.

Elevate the truck with a jack and install the jack stands under the reinforced portion of the front axle. Release the jack to allow the jack stands to fully support the weight of the truck. Finish removing the lug nuts, then pull the wheel from the lugs.

Drive the caliper pins out of the caliper with a brass drift and a hammer.

Compress the caliper on the rotor with a c-clamp to make it release the rotor. Release the c-clamp and quickly remove the caliper from the rotor. Hang the caliper with a short bungee. Do not hang it by the brake line. Do not allow the brake line to become kinked or damaged.

Remove the grease cap located in the center of the rotor by prying the cap loose with a flat screwdriver to expose the wheel nut.

Straighten out the legs of the cotter pin with a pair of needle-nose pliers. Pull the cotter pin out of the lock nut and discard the pin.

Remove the spindle nut by hand. Pull the rotor partially off of the spindle and push it back on again. This will leave the outer bearing and washer exposed for easy removal. Remove the washer and bearing, then slide the rotor off the spindle.

Apply a thin layer of grease on the spindle. Pack the inner bearing and put it in place in the hub. Place the new seal into the recess in the back of the hub. Tap the seal into place with a hammer and a seal driver.

Carefully slide the new rotor onto the spindle. Pack the outer bearing and slide it onto the spindle and into the race on the front of the rotor. Slide the washer onto the spindle and let it rest against the outer bearing.

Install and tighten the spindle nut to 22 to 25 ft./lbs. with a torque wrench. Back the spindle nut off 1/8 of a turn, then tighten the nut as tightly as you can with your fingers.

Install the nut lock and seat it over the spindle nut. Insert the new cotter pin into the spindle. Bend the cotter pin up against the nut with the pliers. Install the grease cap with a hammer by tapping on the cap until it is fully seated.

Place the caliper back in place over the rotor. Lightly coat each caliper pin with anti-seize compound, then drive them into their channels until the lock tabs are engaged on both ends.

Install the tire. Reinstall the lugs nuts then tighten them to 100 ft./lbs. Lower the vehicle off the jack stands.