Trying to replace front brake rotors on a 99 Expy, 4x4 w/ABS. Can't get rotor off. Any suggestions.

 

There was some information posted on the rotors in the last few months, which I used to replace my front rotors this past November.

 

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If you do a search you will find lots of info on this problem. Basically corrosion binds the edge of the hub to the inside of the back of the rotor. What worked for me is removing the caliper mounting bracket--then using the now empty two bolt holes you insert as large a bolt as you can and still get it to slide in the holes. Put a nut on the outside of the bracket--thread the bolt through the nut and continue threading until the bolt comes close to the back of the rotor. Then put the second bolt in. I then put a flat heavy bar across the rotor between the two bolts and the rotor--this helps apply even pressure against the rotor and hopefully prevents warping it. Now work each bolt tighter and rap on the hub/rotor with a big hammer (BFH is the forum term!). I was able to remove both front rotors this way. Some have reported this hasn't worked for them but it did for me.

I then cleaned up the rust--treated the area with Never Seize and put it back together.

Hope this helps you--again do a search--you'll find a lot. In extreme cases some have had to cut V's in the rotor with a Sawzall and then cold chisel it off. Of course destroying the rotor.

 

As long as you don't need to use the rotors again, just get a big hammer and start hitting.

 

took a hammer and prybar to get mine off. needed replaced anyways

 

Had the same experience last weekend with my 99 Expedition. I used the information posted on this site, used the mounting holes to puch with bolts,(did not work), used my torch to heat the rotor,(did not work), big hammer did not work, cutting and grinding did not work, so, Monday morning I took the hubs and rotors to my NAPA store. The machine shop soaked the hub and rotors with PB Blaster and pressed them apart. I would personally not spend time with hammers, heat, bolts, etc. I will let the machine shop do the work. Just my .02 cents worth.
Craig

 

Did mine last week. Use some PB Blaster waited a while then applied heat. I was ready to get out the BF hammer but got lucky and got them moving with a pry bar. Replaced them & generously used some anti-sieze.

Good luck.
Adam

 

Adam:
Thanks for the reply. I too used PB Blaster and the BF hammer but don't have the equipment to apply large quantities of heat. Would not budge. Gave up and took it to a garage. They had to use heat & BF hammer. Cost me $150 labor and I provided the parts.

 

le-ford,

I'm curious as to where you are located. I'm guessing in a rust belt. It seems that some of us have a more severe rotor removal problem than others.

 

I replace the front rotors on my 2003 Expy 2 weeks ago and they were on solid. It took me a couple of dozen whacks with a BFH before they popped free.

 

98expeditionXLT

I live in the south, where we don't usually have to worry about rust. However, I purchased my Expedition from Hertz and I don't know where this vehicle was located in Hertz's rental fleet.

 

HEAT WITH TORCH BANG FROM BACK WITH SLEGE HAMMER FRONTS ARE A BITCH PUT THEM BACK WITH AN TI SEIZE DID IT ONCE MAYBE FORSD HAS A PULLER IT TOOK ME FOREVER

 

I had the same trouble on my 2001 just today. After many blows with a sledge hammer and several soakings with WD-40 the front left rotor cracked and came off in two pieces. The front right simply came off after many more blows. It wasn't easy. I thought after the first hour of trying that I must have missed a bolt or something. I have heard you can cut them off, too. I started this but quickly realized that the recip saw wasn't up to the challenge. Long story short.....they're off and I need two new rotors. Both were destroyed during removal.

 

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