I need to get the brake disc off the front driver tire to replace the u- joint. I have the caliber off and cannot figure how to remove the disc.

Here's a link to remove the caliber. Repair Guides Front Disc Brakes Brake Caliper AutoZone com Here's another link to remove the rotor. Repair Guides Front Disc Brakes Brake Disc rotor AutoZone com

Hi Douglas, I'm glad to help. My first suggestion is to get to complete shaft. This way you want have any problems later on. It's not that much more expensive and you'll be glad you did. Below is the procedure for replacing them.

FRONT DRIVESHAFTS

REMOVAL

1. Raise vehicle on jack stands or centered on a frame contact type hoist. Refer to Hoisting in the Lubrication And Maintenance section of this manual for the required lifting procedure to be used for this vehicle.
2. Remove the cotter pin and nut lock Hub And Bearing To Stub Axle Retaining Nut from the end of the stub axle.
3. Remove the wheel and tire assembly from the vehicle.
4. Remove the wave washer Wave Washer from the end of the stub axle CAUTION: Wheel bearing damage will result if after loosening hub nut, vehicle is rolled on the ground or the weight of the vehicle is allowed to be supported by the tires.
   
5. With the vehicle's brakes applied to keep hub from turning, loosen and remove the stub axle to hub nut.
6. Remove the two front disc brake caliper to steering knuckle attaching bolts Front Disc Brake Caliper Attaching Bolts
7. Remove the disc brake caliper from the steering knuckle. Caliper is removed by first rotating top of caliper away from steering knuckle and then removing bottom of caliper out from under machined abutment on steering knuckle Brake Caliper Mounting To Steering Knuckle
8. Support disc brake caliper assembly by using a wire hook and suspending it from the strut assembly Correctly Supported Disc Brake Caliper Do not allow the brake caliper assembly to hang by the brake flex hose.
9. Remove the brake rotor from the hub and bearing assembly Remove/Install Brake Rotor
10. Remove nut attaching outer tie rod end to steering knuckle Removing Tie Rod End Attaching Nut Nut is to be removed from tie rod end using the following procedure, hold tie rod end stud with a 11/32 socket while loosening and removing nut with a wrench.
11. Remove tie rod end from steering knuckle using Remover, Special Tool MB-991113 Tie Rod End Removal From Steering Knuckle Arm
12. Remove the steering knuckle to ball joint stud, clamping nut and bolt Control Arm To Steering Knuckle Attachment from the steering knuckle.
13. Using a pry bar, separate steering knuckle from ball joint stud Separating Ball Joint Stud From Steering Knuckle Note: Use caution when separating ball joint stud from steering knuckle, so ball joint seal does not get cut. NOTE: Care must be taken not to separate the inner C/V joint during this operation. Do not allow driveshaft to hang by inner C/V joint after removing outer C/V Joint from the hub/bearing assembly in steering knuckle, end of driveshaft must be supported.
    
14. Pull steering knuckle assembly out and away from the outer C/V joint of the driveshaft assembly Steering Knuckle Separation From Driveshaft
15. Support the outer end of the driveshaft assembly. Insert a pry bar between inner tripod joint and transaxle case Disengaging Inner Tripod Joint From Transaxle Pry against inner tripod joint, until tripod joint retaining snap ring is disengaged from transaxle side gear.
16. Hold inner tripod joint and interconnecting shaft of driveshaft assembly. Remove inner tripod joint from transaxle, by pulling it straight out of transaxle side gear and transaxle oil seal Tripod Joint Removal from Transaxle When removing tripod joint, do not let spline or snap ring drag across sealing lip of the transaxle to tripod joint oil seal.

INSTALLATION

1. Thoroughly clean spline and oil seal sealing surface, on tripod joint. Lightly lubricate oil seal sealing surface on tripod joint with fresh clean transmission lubricant.
2. Holding driveshaft assembly by tripod joint and interconnecting shaft, install tripod joint into transaxle side gear as far as possible by hand Tripod Joint Removal from Transaxle
3. Grasp inner tripod joint an interconnecting shaft. Forcefully push the tripod joint into side gear of transaxle, until snap ring is engaged with transaxle side gear. Test that snap ring is fully engaged with side gear by attempting to remove tripod joint from transaxle by hand. If snap ring is fully engaged with side gear, tripod joint will not be removable by hand.
4. Clean all debris and moisture out of steering knuckle, in the area were outer C/V joint will be installed into steering knuckle.
5. Ensure that front of outer C/V joint which fits against the face of the hub and bearing is free of debris and moisture before installing outer C/V joint into hub and bearing assembly Outer C/V Joint Inspection
6. Slide drive shaft back into front hub and bearing assembly. Then install steering knuckle onto the stud of the ball joint assembly Steering Knuckle Separation From Driveshaft
7. Install a new steering knuckle to ball joint clamping bolt and nut Control Arm To Steering Knuckle Attachment Tighten the clamping bolt and nut to a torque of 135 N·m (100 ft. lbs.)
8. Install tie rod end into steering knuckle. Start attaching nut onto stud of tie rod end. While holding stud of tie rod end stationary using a 11/32 socket, Removing Tie Rod End Attaching Nut tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and 11/32 socket Torquing Tie Rod End Attaching Nut , tighten the tie rod end attaching nut to a torque of 54 N·m (40 ft. lbs.)
9. Install braking disc on hub and bearing assembly Remove/Install Brake Rotor
10. Install disc brake caliper assembly on steering knuckle. Caliper is installed by first sliding bottom of caliper under abutment on steering knuckle, and then rotating top of caliper against top abutment Brake Caliper Mounting To Steering Knuckle
11. Install disc brake caliper assembly to steering knuckle attaching bolts Front Disc Brake Caliper Attaching Bolts Tighten the disc brake caliper assembly attaching bolts to a torque of 22 N·m (195 in. lbs.)
12. Clean all foreign matter from the threads of the outer C/V joint stub axle. Install the washer and stub axle to hub/bearing assembly nut on stub axle and securely tighten nut.
13. Install front wheel and tire assembly. Install and tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the required specification. Then repeat the tightening sequence to the full specified torque of 135 N·m (100 ft. lbs.)
14. Lower vehicle.
15. With the vehicle's brakes applied to keep hub from turning, tighten the hub nut to a torque of 244 N·m (180 ft. lbs.) Torquing Front Stub Axle To Hub Nut
16. Install the spring wave washer on the end of the stub axle.
17. Install the hub nut lock, and a new cotter pin Hub And Bearing To Stub Axle Retaining Nut Wrap cotter pin prongs tightly around the hub nut lock as shown in Hub And Bearing To Stub Axle Retaining Nut
18. Check for correct fluid level in transaxle assembly. Refer to Group 21, Transaxle for the correct fluid level checking procedure for the type of transaxle being checked.
19. Set front toe on vehicle to required specification.

loosen the tire lugs while tire on the ground, jack up the vehicle and support it with a jack stand, secure vehicle to prevent rolling and make sure it is in park with the engine off. now finish up loosening the lug nuts and take off the wheel. now open the brake oil filler cap, if it is a disc brake set up get a pry bar or large flat head screw driver and insert it between the brake disc and the rotor and pry it loose to push the brake caliber piston back in its seated position now remove the screws that hold the caliber normaly 2 screws. now clean the caliber with cleaner you might have to push the piston back more using a c-clamp or a large channel lock or you can buy a tool that you twist to seat the piston back into the caliber. mount the new disc pads match them to the old ones re position the caliber into its place and re install the 2 mounting bolts, do the same for the other side and once done get in the car and pump the brake peddle to push the piston against the disc pads mount the wheels and tighten the lug nuts remove jack stand and lower the vehicle, check your brake fluid level and top it off if needed secure oil cap get into the vehicle start it and pump brakes again for several times until it feels hard. now you can take it on a test drive. drive about 20 mph for a several yards come to a complete stop do that for about 8 times to set the brake pads, buy brake pads with life time warranty and save the box and the receipt when you are ready to change them again take them off and put them in the box and take them to be exchanged you can buy a book at the auto parts place they list the complete instruction for disc brakes and brake shoe. for brake shoes we recommend you read the book as there are too many little parts to deal with

TOUGH JOB, YOU HAVE TO REMOVE FRONT TIRE, BLOCK UP CAR,REMOVE BRAKE CALIPER AND BRAKE DISC,HOLD UP WITH PIECE OF WIRE OUT OF WAY,MARK SHOCK STRUT WITH MARKER TO ALIGN LATER, MARK AROUND BOLT HOLES ON STRUT,MARK AND ALIGN CV JOINT GOING INTO TRANSAXLE TO LINE LATER
WHEN ALL IS OUT OF WAY, PULL OR HAMMER OUT CV JOINT AT POINT WHERE IT IS ATTACHED TO TRANSAXLE, BE CAREFUL NOT TO HIT TO HARD, SHOULD PULL OUT EASILY, TO INSTALL DO REVERSE, INSTALL AXLE INTO HOLE IN TRANSAXLE AND PUSH OR TAP IN,LINE UP STRUT AND BOLT HOLES TO MARKS YOU MADE THEN ATTACH TO ROTOR AND ATTACH DISC AND CALIPER, TIGHTEN ALL BOLTS WITH TORQUE WRENCH TO SPECS.PUT TIRE BACK ON CAR, REMOVE BLOCKS, LOWER CAR, TAKE FOR TEST DRIVE,,

Jack up the front end remove tire onthe brake pad assembly there will be two Hex head bolts these will be probably a 3/8 u can use a big Alan wrench u will also need a small pipe to use a breaker bar and some WD 40 as these bolts are probably rusted just a bit,once u have the bolts out u should be able to remove the brake pad assembly,u might need a rubber malet to help with this,OK u got this off take the new brake pads out of the boxs,pay speial attention to the back of them,now take a big screw driver a pry just one of the brake pad off if u do the side with the caliber on it,(this is the round thing that pushes the brake pad on to the disk to stop the car)There is a clip take this clip off look that the back of the brake pad find the new brake pad that has the same notches in it put the clip on it the same way it came off put it back on the caliber,ok take the other one off,nothice the clip might be made in to the brake pad assembly on this side if not put clip in to same notches,Ok now u have replace the brake pads u will notice that the brake assembly will not go back on, not to fear take a Clean rag place it on the pad on the caliber side get a pair of channel locks now compress the caliber abit now it should side right on replace bolts and u are good to go do other side the same way.

Jack up car, remove the wheels, take out the two retaing bolts on the brake caliber, slide caliber up off brake disc, remove old brake pad, use a C-Clamp or big pair of Channel locks to compress the piston in to the brake caliber, Insert new brake pads onto caliber, slide brake caliber back over brake disc, reinstall the 2 retaining bolts. put tire back on. Repeat this till you have replaced all pads that you are going to change. ***Caution.. Before putting the car in gear, crank it up and pump the brake pedal till you have a firm brake pedal. If you fell to do this you will have no brakes due to the pistons on the calibers are compressed and are not seated on the discs.

PATH: Brakes > Front Disc Brakes > Brake Disc (Rotor) > Removal & Installation Removal & Installation

1. Raise and support the front of the vehicle on jackstands. Remove the front wheels.
   
2. Remove the caliper assembly; do not let the caliper assembly hang by the brake hose, instead support it with a piece of wire looped around the front spring or control arm.
   
3. Remove the retaining screw from the brake rotor and remove the rotor from the hub.
   

An impact driver, No. 3 phillips screwdriver bit, and a hammer may be needed to remove the retaining screw. It is fairly easy to destroy the screw slots using an ordinary phillips screwdriver to remove the tightly driven screw (see photo).

1. To install the disc, replace the disc on the hub, screw in the retaining screw and replace the caliper assembly.
   

PATH: Brakes > Rear Disc Brakes > Brake Disc (Rotor) > Removal & Installation Removal & Installation

1. Raise and safely support the vehicle.
   
2. Remove the wheel and tire assembly.
   
3. Disconnect the caliper from the caliper bracket. Support the caliper out of the way with a length of wire. Do not allow the caliper to hang from the brake hose.
   
4. Remove the caliper bracket.
   
5. Remove the two 6mm screws and the brake disc. If the brake disc is difficult to remove, install two 8mm bolts into the threaded holes and tighten them evenly to prevent cocking the rotor.
   
6. Install the rotor in position. Install the two 6mm retaining screws.
   
7. Install the brake caliper. Install the tire and wheel assembly.
   

PATH: Brakes > Rear Disc Brakes > Brake Disc (Rotor) > Removal & Installation Removal & Installation

1. Raise and safely support the vehicle.
   
2. Remove the wheel and tire assembly.
   
3. Disconnect the caliper from the caliper bracket. Support the caliper out of the way with a length of wire. Do not allow the caliper to hang from the brake hose.
   
4. Remove the caliper bracket.
   
5. Remove the two 6mm screws and the brake disc. If the brake disc is difficult to remove, install two 8mm bolts into the threaded holes and tighten them evenly to prevent cocking the rotor.
   
6. Install the rotor in position. Install the two 6mm retaining screws.
   
7. Install the brake caliper. Install the tire and wheel assembly.
   
8. 
   

Thats how I have done it on 2006 250. No C clamp.

Caliper Removal

1. CAUTION: Do not use heat to loosen a seized lug nut . Heat can damage the wheel and the wheel bearings.
   Loosen the lug nuts.
   1. Remove the center cap.
1. With the weight of the vehicle on the wheels, loosen the lug nuts.
1. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS.
   Raise and support the vehicle.
1. Remove the wheel and tire assembly.
   1. Remove the lug nuts.
   1. Remove the wheel and tire assembly.
2. CAUTION: Replace the lining if worn to or past specifications. Replace the brake shoes and linings in complete axle sets. Inspect the brake shoes and linings for wear or contamination.
3. WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE VOMITING. GET MEDICAL ATTENTION IMMEDIATELY.
   Disconnect the front brake hose (2078).
   1. Remove the front brake hose bolt.
   1. Remove the copper washers. Plug the front brake hose.
1. Disconnect the front brake hose
4. Remove the disc brake caliper (2B120).
   1. Remove the two caliper bolts.
   1. Lift the front disc brake caliper (2B121) off the front disc brake caliper anchor plate.
5. On 4x2 vehicles, measure the front disc brake hub and rotor (1102) thickness.
   • Replace the front disc brake hub and rotor if not within specifications 27.7mm Min.
6. On 4x4 vehicles, measure the front disc brake rotor thickness.
   • Replace thhe front disc brake rotor if not within specifications. 27.7mm Min.
7. Inspect the disc brake caliper for leaks.
   • If leaks are found, disassembly is required

Not to bad you will need a ball joint spreader. some sockets wrench's.prybar.Remove the tire then loosen cv bolt. Remove brake caliber and bracket.re move ball joint nut.Remove steering rod nut.Get the ball joint spreader an remove steering rod then remove the ball-joint.Take the cv bolt off grab the strut and pull outward .With a rubber mallet knock cv out of housing.The remove from transmission.you my have pry a little.