Brake Rotors - Rear Pair

This procedure replaces the rear brake rotors on a 1966 Chevrolet Corvette equipped with the 327ci V8, including removal of calipers, spindle components, and rotor replacement.

Warnings

Tools required

Parts

• Rear brake rotor × 2 — Use OEM specification or quality aftermarket
• Rear wheel bearing grease × 1 — High-temperature wheel bearing grease
• Spindle nut cotter pin × 2 — Use OEM specification
• Brake caliper mounting bolts × 4 — Replace if damaged or corroded

Fluids

• DOT 4 Brake Fluid — 1 qt

Preparation

1. Park vehicle on level, solid surface and engage parking brake firmly
2. Place wheel chocks in front of both front wheels
3. Loosen rear wheel lug nuts 1/2 turn while wheels are on ground
4. Raise rear of vehicle using floor jack at rear differential or frame rail
5. Position jack stands under solid frame points near rear axle mounting locations
6. Lower vehicle onto jack stands and verify stability before proceeding
7. Remove rear wheels completely and set aside
8. Spray brake components with brake cleaner and allow to dry to remove dust and contamination

Procedure

1. 1

   Compress brake caliper pistons
   Before removing the caliper, use a C-clamp or brake caliper compression tool to slowly compress the caliper pistons back into their bores. Position the clamp on the back of the caliper body and against the outboard brake pad. This will push brake fluid back into the master cylinder reservoir and make caliper removal easier. Check the master cylinder reservoir and remove fluid if necessary to prevent overflow.
2. 2

   Remove brake caliper mounting bolts
   Locate the two caliper mounting bolts on the rear of the caliper assembly. These bolts secure the caliper to the spindle support bracket. Using the appropriate socket, remove both mounting bolts completely. Support the caliper with one hand as you remove the second bolt to prevent it from falling.
3. 3

   Remove and secure brake caliper
   Carefully lift the brake caliper assembly off the rotor. Do not allow the caliper to hang by the flexible brake hose as this can damage the hose internally. Use wire or a bungee cord to hang the caliper from the suspension or chassis in a position where the brake hose is not stretched or kinked. Ensure the caliper is secure and will not fall during the remainder of the procedure.
4. 4

   Remove spindle dust cap
   Locate the dust cap in the center of the wheel hub. Using a flat screwdriver or pry tool, carefully pry the dust cap from the center of the spindle. Work around the circumference to avoid bending the cap. Set the dust cap aside for cleaning and reinstallation.
5. 5

   Remove cotter pin and spindle nut
   Using cotter pin pliers or needle-nose pliers, straighten and remove the cotter pin that passes through the spindle nut and spindle shaft. Discard the old cotter pin. Using the 1-5/8 inch spindle nut socket or appropriate large socket, remove the spindle nut by turning counterclockwise. The nut may be tight and require a breaker bar.
6. 6

   Remove washer and outer bearing
   Behind the spindle nut, remove the flat washer. The outer wheel bearing will now be loose. Carefully pull the outer bearing from the hub, keeping track of its orientation (tapered side faces inward). Place the bearing in a clean container. If the bearing remains on the spindle, gently work it off by hand.
7. 7

   Remove brake rotor and hub assembly
   Grasp the rotor firmly with both hands and pull straight out from the spindle. The rotor and hub are a single assembly. As you pull the rotor off, the inner wheel bearing and grease seal will remain in the back of the hub. Be prepared to catch the inner bearing if it falls out. Place the rotor face-down on a clean surface to prevent damage to the inner bearing and seal.
8. 8

   Remove inner bearing and grease seal
   With the rotor face-down, use a seal puller or flat screwdriver to carefully pry out the inner grease seal from the back of the hub. The inner wheel bearing will come out with the seal or can be removed separately. Inspect both inner and outer bearings for pitting, scoring, or discoloration. Replace bearings if any damage is present or if they do not turn smoothly.
9. 9

   Clean hub and spindle components
   Using brake cleaner and shop towels, thoroughly clean the inside of the hub bore, removing all old grease. Clean the bearing races (cups) pressed into the hub and inspect for wear or damage. Clean the spindle shaft with brake cleaner, removing all old grease and contamination. Wire brush any rust or corrosion from the spindle threads. Inspect the spindle for damage, scoring, or excessive wear.
10. 10

    Install new brake rotor
    If reusing the hub assembly, remove the old rotor from the hub by removing the 5 retaining bolts. Install the new rotor onto the hub using new or existing bolts, ensuring proper alignment. If using a new complete rotor/hub assembly, proceed directly to bearing installation. Clean the new rotor thoroughly with brake cleaner to remove any protective coating or contamination.
11. 11

    Pack and install inner wheel bearing
    Pack the inner wheel bearing thoroughly with high-temperature wheel bearing grease. Work grease into the bearing from the large end, forcing grease through the rollers until it appears on the opposite side. Place the packed inner bearing into the inner bearing race in the hub. Install a new grease seal by carefully tapping it into place with a seal driver or large socket, ensuring it seats squarely and flush with the hub bore.
12. 12

    Install rotor assembly onto spindle
    Coat the spindle shaft lightly with wheel bearing grease. Carefully slide the rotor and hub assembly onto the spindle, ensuring the inner bearing seats properly on the spindle. Push the assembly fully onto the spindle until it stops. Rotate the rotor by hand to ensure it turns freely without binding.
13. 13

    Install and pack outer wheel bearing
    Pack the outer wheel bearing with wheel bearing grease using the same method as the inner bearing. Install the packed outer bearing onto the spindle, seating it into the outer bearing race in the hub. Install the flat washer over the bearing.
14. 14

    Install and adjust spindle nut
    Thread the spindle nut onto the spindle by hand until snug. Using the spindle nut socket and torque wrench, tighten the nut to 12 ft-lbs while rotating the rotor forward by hand to seat the bearings. Back the nut off one full turn, then hand-tighten the nut until just snug (approximately 10-15 inch-pounds finger tight). The rotor should rotate freely with very slight drag and have no more than 0.001-0.005 inches of end play when pulled outward. If end play is excessive, slightly tighten the nut; if the rotor binds, slightly loosen the nut.
15. 15

    Install new cotter pin
    Once proper bearing adjustment is achieved, align the nearest slot in the spindle nut with the cotter pin hole in the spindle. If necessary, tighten the nut slightly to align the slot (never loosen). Insert a new cotter pin through the spindle and nut slot. Bend the legs of the cotter pin around the nut in opposite directions to secure. The legs should not interfere with the dust cap installation.
16. 16

    Install dust cap
    Pack additional wheel bearing grease into the dust cap cavity (approximately 1/3 full). Tap the dust cap into place on the hub using a rubber mallet or soft-faced hammer, working around the circumference to seat it evenly. The cap should be flush and fully seated.
17. 17

    Reinstall brake caliper
    Remove the caliper from its secured position. Ensure the brake pads are properly positioned in the caliper. Carefully position the caliper over the new rotor, aligning the mounting holes with the spindle support bracket. Insert both caliper mounting bolts and hand-thread them to prevent cross-threading. Tighten the caliper mounting bolts to 70-80 ft-lbs in a crisscross pattern using a torque wrench.
18. 18

    Repeat procedure for opposite side
    Repeat all steps 1 through 17 for the opposite rear brake rotor. Both sides must be completed for proper brake balance and vehicle safety. Ensure all components are installed correctly and all fasteners are properly torqued.

Reassembly

1. Reinstall both rear wheels, hand-threading all lug nuts before tightening
2. Raise vehicle slightly off jack stands using floor jack
3. Remove jack stands and lower vehicle until wheels just contact ground
4. Tighten wheel lug nuts in a star pattern to 70-80 ft-lbs
5. Lower vehicle completely and remove jack
6. Remove wheel chocks from front wheels

Verification

• Check brake fluid level in master cylinder reservoir and top off to proper level with DOT 4 brake fluid if needed
• Pump brake pedal slowly several times until pedal is firm, indicating caliper pistons have extended to contact the new rotors
• With engine off, press brake pedal firmly and verify it holds firm without slowly sinking
• Start engine and verify brake warning light is off and parking brake releases fully
• Perform a low-speed brake test in a safe area to verify proper brake operation before driving at normal speeds
• After first 50-100 miles, re-check rear wheel bearing adjustment for proper end play and spindle nut torque
• Check for any brake fluid leaks around calipers and brake hoses
• Verify both rear wheels spin freely without excessive drag or noise when vehicle is safely raised

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