Front rotor removal.
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New User
Joined: Sep 2007
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Front rotor removal.
I am trying to replace a front rotor on my 2000 ford expy. So far, I have soaked everything in PB blaster, used the bolt and nut method, hammer and sledge to no avail. I guess the next step is one of the following:1
1. Cut off the rotor. I am not sure of the steps to follow. I have seen others say not to cut into the hub, but I am not sure what the hub is? On the rotor itself is the flat area where the pads touch, then there is a stairstep and on that level is where the mounting bolts protrude - is this where the hub is? So if I am cutting, I only want to cut the level where the brake pads touch - is that right? Also, If I use a sawzall, what type of blade works best? I am also not sure what pattern cut and how the rotor splits. It would sure help if there was a video or pictures of the process.
2. If I can't get the rotor off, I need to replace the whole wheel bearing assembly. Is this costly and how difficult would it be?
thanks.
1. Cut off the rotor. I am not sure of the steps to follow. I have seen others say not to cut into the hub, but I am not sure what the hub is? On the rotor itself is the flat area where the pads touch, then there is a stairstep and on that level is where the mounting bolts protrude - is this where the hub is? So if I am cutting, I only want to cut the level where the brake pads touch - is that right? Also, If I use a sawzall, what type of blade works best? I am also not sure what pattern cut and how the rotor splits. It would sure help if there was a video or pictures of the process.
2. If I can't get the rotor off, I need to replace the whole wheel bearing assembly. Is this costly and how difficult would it be?
thanks.
Fleet Owner
Joined: Apr 2008
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From: 0,0,1
Well here a picture of what a hub looks like:
Manufacturer Info
As you can see, you'll want to keep the blade away from the lug nut studs area.
Manufacturer Info
As you can see, you'll want to keep the blade away from the lug nut studs area.
Senior User
Joined: Jun 2004
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if seen a lot of folks have trouble getting the rotors off, but never seen anyone actually fail...so dont give up. A few guys on the forum have cut them off... and said it was a huge PITA. Ive helped afew friends do this on F150s and Expis... and after letting it soak good with PB for about an hour, and taking a 5lb sledge to the rotor, working ur way all the way around and nailing it from every direction, ive eventually got them off without cutting. How many miles are on this set of rotors?
Former Vendor
Joined: Mar 2009
Posts: 8,098
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From: Westford, MA
I've usually been able to get them off with the PB and then a few good wacks with a big hammer. Take a few good wacks but usually they'll loosen up. You're hitting the rotor from the back side right?
Junior User
Joined: Sep 2006
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Had to take the sledge to the ones on my '03 when I switched to slotted/drilled rotors. It did take a while and I did think I was surely gonna rip the hubs or something off with the rotors but all turned out well. Keep soakin and keep a swingin!
Tuned
Joined: Jan 2002
Posts: 491
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From: Fort Fun
I would suggest taking the hub assembly off, turning it over, placing the wheels studs on the ground, then beat with the BAH. That way you have clear sailing with the hammer, and I think that being on the wheel studs would reduce the not-so-good stresses said hammer imparts on the hub assembly.
I had the same problem when changing out the rotor on both our 97 and our 05 Expys. I eventually got them but afterwards, wished I would have gone the route described above.
Big
I had the same problem when changing out the rotor on both our 97 and our 05 Expys. I eventually got them but afterwards, wished I would have gone the route described above.
Big
More Turbo
Joined: Feb 2007
Posts: 546
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I had the same issue a couple months ago. I took it to a mechanic and of course they had to fight it for twice as long as normal so I ended up paying out the butt for new brakes.
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Senior User
Joined: Feb 2004
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From: Omaha, Nebraska USA
I personally don't know how well it works but on person on here puts the tire back on and loosens the lug nuts he drives up and down the drive way hitting the brakes and he claims it loosens up the rotor so you can get it off. One thing to add put a thin coat of antiseez on the hub when you put the new rotor on, it will come off a lot easier next time.
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From: Southern California
Here are two methods for removing stuck rotors...
1. After soaking in PB Blaster (or similar product), looses the lug nuts about 1/2 to 3/4 turn. Place the vehicle in reverse for a few feet, hit the brakes very hard, drive forward and repeat. That should break them loose.
2. if that fails....save your arm. Use a small grinder with a cut off wheel and cut the rotor in half. Typically you won't have to cut the entire thing but when you get close, then a couple of wacks with a BFH will fracture the rotor into a couple of pieces.
1. After soaking in PB Blaster (or similar product), looses the lug nuts about 1/2 to 3/4 turn. Place the vehicle in reverse for a few feet, hit the brakes very hard, drive forward and repeat. That should break them loose.
2. if that fails....save your arm. Use a small grinder with a cut off wheel and cut the rotor in half. Typically you won't have to cut the entire thing but when you get close, then a couple of wacks with a BFH will fracture the rotor into a couple of pieces.
New User
Joined: Mar 2009
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I took the advice from my 28 year ford tech buddy, he said beat the outside face of the rotor with a sledge hammer, the rotor comes off in pieces but it comes off. Had to do it to my 97', worked like a charm. Only takes a few minutes per rotor. It seems abusive and scary but I have had no problems.
Senior User
Joined: Oct 2007
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I personally don't know how well it works but on person on here puts the tire back on and loosens the lug nuts he drives up and down the drive way hitting the brakes and he claims it loosens up the rotor so you can get it off. One thing to add put a thin coat of antiseez on the hub when you put the new rotor on, it will come off a lot easier next time.
that would be me...it works
New User
Joined: Jun 2009
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I just carefully drilled some holes in a circle around the hub and the whole thing popped off with one smack where it had been really stuck. The holes (like 16) allowed it to flex, ruining the integrity. I was, of cource, changing rotors....
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