What size is the torx?

Hey Phil, sounds like you do quite a bit of work on your Tahoe.. you need one of these..

http://repair.chiltondiy.com/Pub/DIY/Product.aspx?ca=Repair&b=28779

Chevrolet Silverado Suburban Tahoe Avalanche GMC Yukon Yukon XL Yukon...

Chevrolet Silverado GMC Sierra 1999 thru 2006 2WD and 4WD

1 Park your Buick on a level surface and shift the transmission to Neutral.

2 Open the hood and draw enough brake fluid from the master cylinder reservoir to bring the level down midway between the Full and Add marks if necessary. Use a new or clean turkey baster and a proper container. Then replace the reservoir cap but do not tighten.

• 3 Loosen the wheel lug nuts on both front tires using a lug wrench.
  

• 4 Raise the front of your vehicle using a floor jack and support it on jack stands.
• 5 Secure the rear wheels with chocks.
• 6 Finish removing the front wheel/tire assemblies.
• 7 Reinstall two wheel lug nuts, hand tight, on the hub assembly you will be working on first. This will prevent the rotor from sliding off the hub.
• 8 Force the brake caliper piston partially into its bore using a large C-clamp, just enough to allow it to clear the rotor when removing the caliper.
• 9 Unscrew and remove the lower caliper pin bolt using a Torx bit socket and ratchet.
• 10 Rotate the brake caliper upwards and secure it to the coil spring with a piece of wire.
• 11 Remove the inner brake pad from the brake caliper bracket and place it against the caliper piston.
• 12 Seat the caliper piston into its bore with the large C-clamp by pushing the inner pad with the clamp screw. Then remove the inner pad from the caliper.
• 13 Remove the outer brake pad and brake pad retainers from the brake caliper bracket.

Installing the Brake Pads

• 14 Clean the brake assembly of brake dust using brake parts cleaner spray and a clean, lint-free cloth or towel.
• 15 Install the brake pad retainers on the caliper bracket.
• 16 Inspect the boot around the caliper piston and make sure it is laying flat. If necessary, use a blunt plastic stick or suitable tool to set the inner edge of the boot flat while avoiding damage to the boot.
• 17 Set the new brake pads on the brake caliper bracket.
• 18 Untie the brake caliper and rotate it back into position over the brake pads and bracket.
• 19 Start the caliper lower-pin bolt by hand. Then tighten it with the Torx bit socket and ratchet.
• 20 Climb in behind the steering wheel and depress the brake pedal only about 2/3 of its normal travel distance. Release the pedal and wait for about 15 seconds before depressing the pedal again. Repeat this procedure until you feel a firm brake pedal.
• 21 Remove the two wheel lug nuts from the brake assembly.
• 22 Replace the brake pads on the other front wheel starting with Step 7, from the previous section, through Step 8 of this section.
• 23 Reinstall the wheel/tire assemblies.
• 24 Lower the vehicle and remove the chocks.
• 25 Add new brake fluid to the master cylinder reservoir to bring the level up to the Full mark if necessary. Then tighten the cap.

Buy F150 Parts.

To front pads, tighten the caliper pins to 16-30 ft. lbs. (22-40 Nm) on 1997-98 F-250HD, F-350 and F-Super duty models. Tighten the caliper pins to 21-26 ft. lbs. (28-36 Nm) on the F-150, F-250, Expedition and Navigator. Tighten the caliper pins to 42 ft. lbs. (56 Nm) on the 1999-00 F-250SD, F-350 and F-Super Duty models.

To install the rear disc brake caliper onto the rear support bracket. Tighten the caliper retaining pins on the F-150, F-250, Expedition and Navigator to 20 ft. lbs. ( 27 Nm). Tighten the caliper retaining bolts on the 1999-00 F-Super Duty models to 27 ft. lbs. (36 Nm.)

Hope helps.

No...absolutely not. However....it is more likely that the lugs were not tightened in the first place that caused the lugs to break. Wrong size tire will not do that. Furthermore...its a pretty simple fix. Jack up the wheel....pull off the caliper bracket and rotor will slide right off. Then you have a hub in front of you with all of the broken studs facing you. Take a hammer...smack out the studs from the hub. They are splined in there....one good hit can smack them out. Call your local NAPA or Auto Zone...give them your vehicle info and tell them you need all of the lug studs and lug nuts for on side of the vehicle. They should have them in stock. The rest is just reversing your removal procedure. Turn the wheel out...smack them in till the flat base of the stud is flush with the back of the hub. put rotor and caliper back on....and then the tire....tighten the lug nuts! You are good to go. Probably a $20 repair. Caliper bolts may be very tight....they use lock tight in the factory. You should get ahold of a good 1/2" breaker bar

common hand tools and a torque wrench

No, but I would replace the rotors. Turning them usually winds up getting them warped as soon as they heat up and/or you hit a puddle of water..also, you will need a torque wrench and standard automotive tools, Jack and stands and a vice..

1 Place the Transfer shift in the 2H position.
Raise and support the front of the vehicle safely on jackstands.
2 Remove the wheel and tire assembly.
3 Loosen the hub to rotor retainer bolts.
4 Remove the brake caliper mounting bolts and carefully remove the caliper (along with the brake pads) from the rotor. Do not disconnect the brake line. 5 Secure the caliper out of the way with the flexible line still connected.

Once the hub/rotor is removed from the vehicle the wheel bearings may be cleaned and repacked or the bearings and races may be replaced. For more information, please refer to the wheel bearing procedures in General Information & Maintenance of this manual.

6 Remove the hub nut using hub wrench J-29020-A or equivalent.
7 Remove the hub cap assembly retainer bolts.
8 Remove the spindle nut, washers, and other components. Remove the hub/rotor, being careful not to drop the outer wheel bearings. As the hub/rotor is pulled forward, the outer wheel bearings will often fall forward.
9 Once the hub/rotor is removed, remove the retainer bolts securing the rotor and hub together. Inspect the hub and replace if needed.

To install:
1 With the rotor secured in a vise, attach the wheel hub to the rotor using the retainer bolts. Tighten the bolts to 47-58 ft. lbs. (61-75 Nm). Apply 2.12 oz. (60 gm) of grease to the hub before installing.
2 Carefully install the wheel hub/rotor over the spindle.
3 Install the bearings washers and other components. 4 Position the lock washer so the hub cap assembly bolt holes line up properly.
5 Install the spindle washer and nut and secure using hub wrench J-29020-A or equivalent. Preload the bearing to 3.31 lbs. (1.5 kg).
6 Install the inner cam and any shims. Install the hub cap assembly and secure in place with retainer bolts. 7 Tighten grade M8 bolts to 17-22 ft. lbs. (22-29 Nm), tighten grade M10 bolts to 40-47 ft. lbs. (52-61 Nm).
8 Install the brake caliper.
9 Install the tire and wheel assembly.
10 Remove the supports and carefully lower the vehicle.

Removing: Loosen lug nuts (7/8") and spindle nut (36mm). Lift truck. Remove lug nuts, spindle nut, and wheel. Remove 2 bolts (3/8" allen) holding calipers on. Hold the calipers up with a bungee cord. I attached it to the sheet metal of the fender. Remove 4 bolts (15mm) from rear of hubs. Once these bolts are removed you can move the shield that is in-between the hub and the axle(I think). You are moving it to get access to the allen bolt that holds the ABS sensor on. Once you move the shield then you can look through the top of the rotor through the slots and see the sensor line and bolt. I don't remember what size allen this one took. You do need a long allen wrench though. Disconnect sensing line from hub. Now the rotor is ready to come off. I had to use a pry bar to remove this gently working each side until it popped off. Once the rotor is removed, you need to hammer out the lug bolts. Then you have to tap the rotor away from the hub. This took a little work. Then check each of the lug bolts by screwing the lug nuts on them. They should go all the way down by hand. If they don't - go buy new bolts $2 a piece. Installing: Position new rotor on hub. Get some dry ice from your local grocery store and freeze the bolts for about 10 minutes. Pull one bolt out of the ice at a time and install on the rotor and tighten the bolt with the lug nut. I put the nuts on upside down and used a 7/8" wrench and mallet to tap on the wrench to get these as tight as possible. You also have to tap on the head of the bolt and repeat the wrench tapping. Do this for each bolt pulling one out of the ice at a time. You do not have to get the rotor and hub completely together but get it as close together as possible. Once all of the lug bolts are in it is time to put the rotor on the truck. Ensure the shield is on the spindle and install the rotor, again, this takes some work. Once the rotor is on, connect the ABS sensing line. Line up the shield and install 4 bolts to rear of hub. You can align these by moving the hub, not the rotor. Install the caliper, remember to put brake grease on these 2 bolts. You may have to compress the caliper slightly. To do this remove the brake pad that has the circular part of the caliper touching it. Open the brake fill cap on the master cylinder. Use a C-clamp to compress the circular part. Reinstall the brake pad and brake fill cap. Install the caliper. Install the wheel and tighten lug nuts. I used a cheater bar on my tire iron and ensured that the lug bolts were flush with the head of the lug nuts. Then I removed the wheel to verify that the gap between the rotor and the hub was gone. Reinstall wheel, tighten lug nuts, and tighten spindle nut. Once both brakes have been replaced, start up the truck and pump the brakes several times till you feel some tension when pressing them.

6 mm to small 8 mm to big, how about 7 mm would you not think ??

Remove wheel, caliper and rotor. hit it solidly with a good hammer and it should go right through and fall out. Sometimes you will need to grind a bit off the side of the new one to get it past any obstructions. That will not harm its performance in any way unless you take way more than you need to off of it.To get it all the way back in, oil the threads, put a stack of large washers on it and tighten the nut on backwards till you draw it all the way in.

here is procedure

Section 04-01: Suspension and Wheel Hubs, Front 1996 Taurus, Sable Workshop Manual
REMOVAL AND INSTALLATION Wheel Hub Bolt Removal

1. Raise vehicle on hoist.
   

1. Remove wheel and tire assembly. Refer to Section 04-04 .
   

1. Remove disc brake caliper (2B120), and front disc brake rotor (1125). Refer to Section 06-03 .
   

Brake Shoe and Lining Removal

1. Remove brake master cylinder filler cap (2162). Check fluid level in brake master cylinder reservoir (2K478). Remove brake fluid until brake master cylinder reservoir is half full. Discard removed fluid.
   

1. Raise vehicle on hoist. Refer to Section 00-02 .
   

1. Remove wheel and tire assembly from front disc brake rotor mounting face. Use care to avoid damage or interference with disc brake caliper (2B120), front disc brake rotor shield (2K004) or front wheel knuckle (3K185).
   

1. Remove rear brake pin retainers (2N386). ( I think it is a T 40 torx bit you need)
   

1. NOTE: It is not necessary to disconnect hydraulic connections.
   
   Lift disc brake caliper from front disc brake caliper anchor plate (2B292) and front disc brake rotor (1125). Do not pry directly against metal caliper piston or damage will occur.
   

1. Position disc brake caliper out of the way and support with wire to avoid damaging the disc brake caliper and front brake hose (2078).
   

1. Remove outer brake shoe and lining (2001) assembly from front disc brake caliper anchor plate.
   

1. Remove inner brake shoe and lining assembly.
   

1. Position lug bolt (1107) to clear front wheel knuckle (3K185).
   

1. Remove lug bolt from wheel hub (1104).
   
   
   
   

Installation

1. Install lug bolt into wheel hub.
   

1. Using a lug nut (1012), seat wheel hub bolt into wheel hub.
   

1. Install front disc brake rotor and disc brake caliper. Refer to Section 06-03 .
   

1. Install wheel and tire assembly. Tighten lug nut to 115-142Nm (85-104 lb-ft).