This is a great write up!

On the locating screw... with the calipers installed, how could the rotor possibly fall off during a wheel change? Just curious, as many other cars I've worked on don't have that screw, and rotors falling off aren't much of an issue.

 

Great write up, and if I could add a couple of ideas also.
When you first remove the rotor, take some emry cloth and sand the rust from the hub and apply a very thin film to prevent them from rusting which will make taking them off in the future a lot easier.
Always grease the studs before torquing them to 102 foot pounds.
Always do a full 2 quart DOT 4 brake flush and use a good synthetic for a firm pedal.
Might also replace the rubber brake lines if over 100,000 mile for safty reasons as well as a firmer brake pedal.

 

The screws hold the rotors on the hub while its moving down the assembly line before the calipers are installed. They do make it easier when doing brake work (as opposed to spinning a lug nut on to keep the rotor in place while installing the caliper)

 

Rotor can't fall off with caliper on Just sayin.

 

Man, good call on the calipers not allowing it to fall off... I guess I was seeing these things for so long without the calipers on them. Doh!

Thanks, Mike, for the tips! I plan on going stainless lines in the Spring.

 

Great write up. I am attempting to do the same on my 2004 Discovery. I am not having any luck finding a #4 Phillips head bit anywhere. Sears does not have one in its current impact driver kit. AutoZone and Advance Auto don't carry them and even NAPA is a no go. Any ideas? Thanks.

 

old screwdriver, punch, small cold chiesel any of these and then a hammer.

 

Thanks. I'll give it a try.

 

Update. Tried the impact wrench with a #3 after soaking it with rust penetrant. Gave it a few taps and they came loose on both sides. Front brakes and rotors done. Rear will have to wait till Saturday. Also have to replace the hub on the driver's side.