After just doing a brake job on my 2002 2500 with 4 wheel disc brakes I thought I'd post some photos with some maybe helpful information to those seeking information before they jump in. This is a Dana 70 and does NOT APPLY to duallies. After doing many searches here at TDR to find info for myself I did decide to pull the wheels the day before doing the job and spraying a quality parts loosen-er spray around the hub and lug studs there the rotors are attached. I did a little beating on the rotors between the lug studs the night before to work the parts loosen-er in.
It's pretty straight forward removing the calipers (2 bolts each) and caliper mounting brackets (2 bolts each). You only need to remove the caliper mounting brackets if you are replacing rotors. NOTE: If you are just replacing pads they are removable once the calipers are out of place. NOTE: If you are replacing or resurfacing rotors once the caliper bolts are removed, tie up or secure calipers out of the way so they don't hang by the hoses and then remove rotors.
Tools need:
Quality Parts Loosen-er
High Temp Anti Seize
Non hardening high temp loc tight for caliper bracket mounting bolts
Big Hammer or air hammer w/ flat driver chisel
Flat bladed screw driver
Pry bar
1/2" & 3/8" drive ratchets
15/16" - 6 pt - 1/2 drive socket for wheel lugs (My lug nut torque is 140' pounds)
13/16" - 6pt - 1/2 drive socket for rear caliper mounting bracket bolts
1/2" - 6 pt - 3/8" drive socket for rear caliper mounting bolts
T-45 - 3/8" drive Torx driver for front caliper mounting bolts
5/8" - 12 point - 1/2" drive socket for front caliper mounting bracket bolts
3/8" line wrench for bleeder screws
Torque wrench or wrenches capable of attaining 20-210 ft lbs
In going through the TDR archives there was some question as to the validity of the 210' pound spec on the rear caliper bracket mounting bolts. They did safely go to 210' foot pounds of torque on mine.
Here is a picture of the rear after the rotor was removed. Notice the parking brake shoes, the drum for the parking brake is incorporated on the inside of the rear portion of the rotor:
Here is a picture of the front after rotor removal:
Here are the caliper mounting brackets after removal that includes the old disc brake pads:
Here is the front brake backside after reassembly:
Here is the rear brake backside after reassembly:
And here are the outside views after reassembly:
Front
Rear
Anti seize applied lightly between the hub and the rotors prior to assembly.
Linear Mode
