This procedure covers removal and replacement of a single front brake rotor on a 1966 Chevrolet Corvette with 327ci V8, including removal of the caliper and spindle components necessary to access the rotor.

Warnings

Tools required

Parts

• Front brake rotor × 1 — Use OEM specification or quality aftermarket
• Cotter pin (1/8" diameter) × 1 — Standard 1/8" x 1.5" cotter pin
• Outer wheel bearing seal × 1 — Use OEM specification
• Wheel bearing grease × 1 — High-temperature wheel bearing grease

Preparation

1. Park vehicle on level, solid ground and place transmission in Park (automatic) or 1st gear (manual)
2. Block rear wheels with wheel chocks on both sides
3. Loosen front wheel lug nuts 1/2 turn while vehicle is on the ground
4. Jack up front of vehicle at the frame rail (NOT the fiberglass body) and secure on jack stands rated for vehicle weight
5. Remove front wheel completely
6. Place drip pan under work area to catch any grease or brake fluid
7. Spray brake assembly with brake parts cleaner and wipe down to remove dust (do not blow with compressed air due to asbestos)

Procedure

1. 1

   Remove brake caliper mounting bolts
   Locate the two caliper mounting bolts on the rear side of the caliper assembly. Using a 9/16" socket and ratchet, remove both caliper mounting bolts completely. These bolts thread into the steering knuckle. Keep these bolts in a safe place as they will be reused.
2. 2

   Support and remove brake caliper
   Carefully lift the caliper assembly straight up and off the rotor. Do NOT let the caliper hang by the rubber brake hose. Use a bungee cord or mechanic's wire to hang the caliper from the upper control arm or frame. Ensure there is no tension or strain on the brake hose.
3. 3

   Remove dust cap from spindle
   Locate the chrome or steel dust cap in the center of the hub. Using needle-nose pliers or by carefully prying with a flat blade, remove the dust cap from the spindle. This exposes the spindle nut and cotter pin.
4. 4

   Remove cotter pin from spindle nut
   Using cotter pin pliers or side cutters, straighten the ends of the cotter pin that passes through the spindle nut and spindle. Pull the cotter pin out and discard it. A new cotter pin must be used during reassembly.
5. 5

   Remove spindle nut and washer
   Using a 1-1/16" socket, remove the large spindle nut by turning counterclockwise. Remove the flat washer behind the nut. Note the position and orientation of the washer for reassembly.
6. 6

   Remove outer wheel bearing
   With the spindle nut removed, grasp the rotor assembly and pull it slightly toward you. The outer wheel bearing will become loose. Remove the outer bearing from the spindle and place it in a clean container with the bearing race. Keep track of which bearing came from which side.
7. 7

   Remove rotor and inner bearing assembly
   Pull the rotor straight off the spindle. As you remove it, the inner wheel bearing and grease seal will remain in the rotor hub. Place the rotor face-down on a clean work surface. Remove the inner bearing and grease seal from the rear of the hub. Inspect both bearings and races for wear, pitting, or discoloration.
8. 8

   Clean spindle and inspect components
   Thoroughly clean the spindle with brake parts cleaner and a shop towel. Inspect the spindle for scoring, wear, or damage. Wire brush any rust or corrosion. Check that both bearing races in the old rotor are in good condition. If races show any wear, the new rotor must have races installed.
9. 9

   Prepare new rotor for installation
   Ensure the new rotor has bearing races properly seated in both the inner and outer positions. Clean the rotor hub bore and bearing surfaces with brake cleaner. Apply a light coat of anti-seize to the spindle (avoiding the bearing surface area). Pack both wheel bearings completely with high-temperature wheel bearing grease using a bearing packer or by hand.
10. 10

    Install inner bearing and seal
    Place the greased inner wheel bearing into the inner bearing race of the new rotor. Install a new grease seal squarely over the inner bearing, tapping it gently with a seal driver or large socket until it is fully seated and flush with the hub surface.
11. 11

    Install rotor onto spindle
    Carefully slide the new rotor assembly onto the spindle, being careful not to damage the inner grease seal. Push the rotor fully onto the spindle until it seats against the inner bearing.
12. 12

    Install outer bearing, washer, and spindle nut
    Install the greased outer wheel bearing onto the spindle, followed by the flat washer. Thread the spindle nut onto the spindle by hand, turning clockwise until finger-tight.
13. 13

    Adjust wheel bearing preload
    Using a 1-1/16" socket and torque wrench, tighten the spindle nut to 12 ft-lbs while rotating the rotor forward to seat the bearings. Back the nut off one full turn, then hand-tighten the nut until just snug while rotating the rotor. Back off the nut 1/6 to 1/4 turn until the nearest cotter pin hole in the spindle aligns with the castle slots in the nut. The rotor should spin freely with only slight drag and have 0.001-0.005 inches of end play.
14. 14

    Install new cotter pin and dust cap
    Insert a new cotter pin through the spindle nut and spindle. Bend the ends of the cotter pin over to secure it (one end up, one end down or both wrapped around the nut). Tap the dust cap back into place using a soft-face hammer, ensuring it seats fully.
15. 15

    Reinstall brake caliper
    Remove the support wire or bungee cord from the caliper. Position the caliper over the new rotor, aligning the mounting bolt holes with the threaded holes in the steering knuckle. Install both caliper mounting bolts and tighten them securely with a 9/16" socket.

Reassembly

1. Reinstall the wheel onto the hub, threading lug nuts by hand initially
2. Lower vehicle until tire just touches ground (keeps wheel from spinning while tightening)
3. Tighten lug nuts in a star pattern to proper specification
4. Fully lower vehicle and remove jack stands
5. Torque lug nuts to final specification in star pattern
6. Pump brake pedal several times until firm before attempting to move vehicle

Verification

• With vehicle still raised, spin the rotor by hand - it should rotate freely with only slight bearing drag and no grinding or rubbing
• Check for any lateral (side-to-side) movement at the top of the tire - there should be minimal play (0.001-0.005 inches)
• Pump brake pedal several times - it should become firm and hold pressure
• Test drive vehicle in a safe area at low speed, verifying smooth braking with no pulsation, noise, or pulling
• After test drive, recheck lug nut torque
• After 50-100 miles, recheck wheel bearing adjustment and lug nut torque

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