Hi, I have a '98 F-150 4x4, 4.6, auto, 220K, S-cab. I was doing a front brake job and I was unable to remove the drivers side brake rotor. The previous times I redid the front brakes, the rotors just slipped off with no effort. This time, the passenger side rotor needed to be struck several times with a 2 pound hammer to get it off. The driver side rotor will not come off. I tried a Harbor Freight large 3-jaw puller, with a hydraulic jack cylinder built into it, rated at 12 tons and it would not budge. I also tried heating it with two Benzomatic torches and using the puller there is still no movement at all.

I finally gave up and took it to a repair shop. They were also unable to remove the rotor and have ordered a new hub. The rotors that I have issues with were new when installed and purchased at NAPA.

Has anyone else had this problem?

Thanks in advance.

RotorPuller-2.jpg Photo by shickman_photo | Photobucket

 

Small LP torches are sometimes not enough, but a heating with an oxy-acetylene/oxypropane torch can break such things loose.

 

never had a disc that tight, but several brake drums were that way. I take a hand drill with a 3/16 inch bit and drill 3 or 4 holes on the disc ID where it pilots to the hub. This allows the disc room to expand, and also a hole to shoot penetrant into. Normally i have not needed heat after this, but it sure dont hurt. Take a small air/ electric grinder with a small wheel or burr and take a couple thousands off the ID of the new brake disc. Then install anti-sieze prior to install.

 

I had to use a 16 pound sledge to pound mine off. I then applied some anti seize and have been good ever since.

 

Up here in Nova Scotia Canada we have a big problem with salt/rust. The lip on the inside of the rotor builds up with rust and will not come out over the hub. We usually end up ruining the rotor by beating on it to knock the rust off the inside so it will pull off the hub.