I had to break down and get my front rotors off this weekend on my 97 4x4. They are gouged badly, less than half of the back surface isn't rusty and they are simply dangerous over 40 mph. I tried four years ago with 60,000 miles and failed and ending up just slapping on new pads. Now at 90,000 miles they are that much more rusted on. I brought it in to a local garage hoping for a flat rate, but they immediately identified the rusty rotor problem and they would only go per hour, saying it may take 2-4 hours to get them off @ $ 80/hr, the whole job could go $600- $900 with parts and they couldn't guarantee that they would not damage the hub with heat and banging.

So I decided to give it a try with some of the great forum ideas. I loosened the wheel lug nuts and slammed the brakes a few time from 10 mph, put it up on jacks, took off the calipers and got behind the rotor/ hub interface with a sharp tool and scraped away as much rust as possible. I then used penetraing oil liberally behind the hub and through the lug holes and front hub.

The I watched the football game for a few hours, respraying at half time.

After the game, I put two 1/2" x 2 Grade 8 bolts through the caliper holes with a nut on the back and pressed both against the rotor, plus a few whacks with a hammer. I did this in about six different rotations, almost giving up when I heard a big snap. I was happy to find it was the rotor popping and not the rotor bracket breaking, a few more whacks and it was off. No heat, no heavy pounding. I did buy a couple sawzall blades to cut them off in case this failed.

New Power Slot rotors and Hawk HPS pads are on, plus lots of antisieze. Total cost about $280. Night and day difference in braking. I can now go over 40 mph without fear.

Thanks Ford forum gurus!!. Godd stuff on here.

 

Hey, nice work!!! Glad to hear someone won the rotor war in one battle. Rob

 

I just checked my rotors today, and they are going to have to come off and be resurfaced. The truck must have been sitting a lot in the previous owners garage, because the back sides of the rotors are only using 75% of what they should, they are all rusty. I also tightened the wheel bearings as needed, and lubed the slides. But they will soon be coming off.

Hey guys, i havent checked at all, is there a drain plug for manual transmissions?