DIY D22 Front Disc Rotor Removal/Replacement

First of all, a warning:
IF YOU HAVE ANY DOUBTS ABOUT THIS WHATSOEVER, DO NOT ATTEMPT IT WITHOUT COMPETENT SUPERVISION OR GIVE YOUR TRUCK TO QUALIFIED PERSONS.

Alright here's a bunch of photos and a rough process (that I followed) to Remove my front disc Rotors for machining, same steps can be followed to replace rotors.

Materials:
- High Temp Bearing Grease
- Brake Cleaner
- Rotors - part# DBA 629 (RDA = $55ea, DBA = $80ea) (Part changes for different variants please check with supplier)

Tools:
- 6mm Hex Key
- 14mm Socket
- 19mm Socket/Spanner + Breaker Bar
- #2 Phillips screwdriver
- Circlip remover
- Lock Nut Removal Tool

First things first, Park the truck on some solid flat ground, and chock the rear wheels (not entirely necessary, but a good safe guard nonetheless)

Loosen the wheel nuts and the Hex bolts on the hub cover before jacking the car up off the ground,





jack it up high enough that you can get a chassis stand in underneath the lower control arm/Chassis rails. NEVER WORK ON A CAR SUPPORTED ONLY BY A JACK.



Undo the two 19mm bolts that hold the brake Carrier to the spindle.

Slide the Carrier+caliper off and tuck it away so that it can't fall nor hang by the brake line, fencing wire, bungy straps or cable ties work well. i found that i could safely tuck it away on the upper control arm.

Completely loosen and remove the hub cover


Remove Circlip thats holding in the drive clutch and remove drive clutch


Remove 2 x phillips Screws holding in Lock Washer and Remove Lock washer


Remove Lock nut with Special Tooling (if you don’t have tool, hammer and punch will do, it is not on that tight)

Pull rotor out and remove front bearing and remove rotor


once the rotor + hub is out, remove the 6 x 14 mm bolts and then you rotor and hub should be seperated



when replacing everything just do bove steps in reverse

key thing to do is regrease bearings and bearing should be preloaded to the below specs its done as follows:
1) tighten wheel bearing lock nut to 85 N.m while roating the rotor
2) then loosen it all the way
3) then tight lock nut back upto 1 N.m (basically hand tight)



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Congratulations, you've just successfully changed your brake pads.
(Some images are from other threads hope those guys dont mind)

gazza414 said:

Where did you find the "special tool" ?...ebay etc

Click to expand...

ebay is the cheapest $17.00 (4H501 is the part number)

http://www.ebay.com.au/itm/Hub-Nut-...lothing_Merchandise_Media&hash=item565d516202

This video basically goes through this whole process but spends more time on showing you how to grease/pack the bearings - https://www.youtube.com/watch?v=g0CH0GtAUoA

That's a great link ^^^
thanks

to keep it as a uncluttered diy, this thread is now closed
thanks gner8r for your efforts.....contact admin or mods for editing
cheers