Installing new rotors
Thread Starter
Pro
Joined: Oct 2006
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From: Independence Mo.
Installing new rotors
I am installing new rotors on my 02 and can not seam to get the stock rotor off. I have removed the caliper and the rotor will not slide off. Any help would be appreciated
Le Mans Master
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From: Winchester TN
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Hi Black Bat -
Tap around the face of the rotor (between the lug studs) with a hammer - taking care not to bung up your lug stud threads.
Then grab the outside edge of the rotor in two places 180 degrees apart and wiggle it off -
IF that does not work, use some penetrating lubricant (PB Blaster, WD-40 etc.) around the inner diameter of the rotor where it is slid onto the hub.
If it is a rear rotor, you also need to remove the parking brake cable and ensure the parking brake shoes are not interfering with removal.
Sometimes you just have to do a little hammer work to get them off, just be careful and only hammer on the old rotor that will not be re-used.
One other thing - you did remove the caliper and caliper mounting brackets, right? The rotor cannot come off with the caliper mounting brackets still in place - I just leave the caliper on the bracket and remove the two bracket bolts.
best regards -
mqqn
Tap around the face of the rotor (between the lug studs) with a hammer - taking care not to bung up your lug stud threads.
Then grab the outside edge of the rotor in two places 180 degrees apart and wiggle it off -
IF that does not work, use some penetrating lubricant (PB Blaster, WD-40 etc.) around the inner diameter of the rotor where it is slid onto the hub.
If it is a rear rotor, you also need to remove the parking brake cable and ensure the parking brake shoes are not interfering with removal.
Sometimes you just have to do a little hammer work to get them off, just be careful and only hammer on the old rotor that will not be re-used.
One other thing - you did remove the caliper and caliper mounting brackets, right? The rotor cannot come off with the caliper mounting brackets still in place - I just leave the caliper on the bracket and remove the two bracket bolts.
best regards -
mqqn
Instructor
Joined: Nov 2006
Posts: 139
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From: CHICOPEE MA
Hi Black Bat -
Tap around the face of the rotor (between the lug studs) with a hammer - taking care not to bung up your lug stud threads.
Then grab the outside edge of the rotor in two places 180 degrees apart and wiggle it off -
IF that does not work, use some penetrating lubricant (PB Blaster, WD-40 etc.) around the inner diameter of the rotor where it is slid onto the hub.
If it is a rear rotor, you also need to remove the parking brake cable and ensure the parking brake shoes are not interfering with removal.
Sometimes you just have to do a little hammer work to get them off, just be careful and only hammer on the old rotor that will not be re-used.
One other thing - you did remove the caliper and caliper mounting brackets, right? The rotor cannot come off with the caliper mounting brackets still in place - I just leave the caliper on the bracket and remove the two bracket bolts.
best regards -
mqqn
Tap around the face of the rotor (between the lug studs) with a hammer - taking care not to bung up your lug stud threads.
Then grab the outside edge of the rotor in two places 180 degrees apart and wiggle it off -
IF that does not work, use some penetrating lubricant (PB Blaster, WD-40 etc.) around the inner diameter of the rotor where it is slid onto the hub.
If it is a rear rotor, you also need to remove the parking brake cable and ensure the parking brake shoes are not interfering with removal.
Sometimes you just have to do a little hammer work to get them off, just be careful and only hammer on the old rotor that will not be re-used.
One other thing - you did remove the caliper and caliper mounting brackets, right? The rotor cannot come off with the caliper mounting brackets still in place - I just leave the caliper on the bracket and remove the two bracket bolts.
best regards -
mqqn
Don't let caliper hang from brake hose, so as not to risk damage to brake hose. Just my .02
Instructor
Joined: Aug 2004
Posts: 132
Likes: 1
Hi Black Bat -
Tap around the face of the rotor (between the lug studs) with a hammer - taking care not to bung up your lug stud threads.
Then grab the outside edge of the rotor in two places 180 degrees apart and wiggle it off -
IF that does not work, use some penetrating lubricant (PB Blaster, WD-40 etc.) around the inner diameter of the rotor where it is slid onto the hub.
If it is a rear rotor, you also need to remove the parking brake cable and ensure the parking brake shoes are not interfering with removal.
Sometimes you just have to do a little hammer work to get them off, just be careful and only hammer on the old rotor that will not be re-used.
One other thing - you did remove the caliper and caliper mounting brackets, right? The rotor cannot come off with the caliper mounting brackets still in place - I just leave the caliper on the bracket and remove the two bracket bolts.
best regards -
mqqn
Tap around the face of the rotor (between the lug studs) with a hammer - taking care not to bung up your lug stud threads.
Then grab the outside edge of the rotor in two places 180 degrees apart and wiggle it off -
IF that does not work, use some penetrating lubricant (PB Blaster, WD-40 etc.) around the inner diameter of the rotor where it is slid onto the hub.
If it is a rear rotor, you also need to remove the parking brake cable and ensure the parking brake shoes are not interfering with removal.
Sometimes you just have to do a little hammer work to get them off, just be careful and only hammer on the old rotor that will not be re-used.
One other thing - you did remove the caliper and caliper mounting brackets, right? The rotor cannot come off with the caliper mounting brackets still in place - I just leave the caliper on the bracket and remove the two bracket bolts.
best regards -
mqqn
Only thing I could add is if you have tried all the above then you may have to heat the rotor with a torch. This would be a very unusual thing to have to do but road crime and heat can weld the rotor onto the hub.Be sure and clean with a wire brush the mating surfaces before you install your new rotors.
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From: Kerrville, Texas USA Hook 'em Horns!
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mggn posted some very good instructions. 
I can not stress enough though to be careful with the rears. The little clip that hold the e-brake in place is a major pain to re-install.
Good luck,
Larry
I can not stress enough though to be careful with the rears. The little clip that hold the e-brake in place is a major pain to re-install.
Good luck,
Larry
Thread Starter
Pro
Joined: Oct 2006
Posts: 576
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From: Independence Mo.
The rotor must be rusted on. I am soaking with PB as we speak. I have supported the rotor on a box as I will be painting it soon. I have hand threaded the lugs on the studs in case of damage. I will try all of the above. Thank You
Melting Slicks
Joined: Apr 2005
Posts: 3,469
Likes: 4
Keep at it. Mine were a bear to get off, too. I tired wd40, hitting the backsides with a mallet, curisng, praying, etc. Eventually the thing that worked was rigging up a pretty thick metal plate over the studs, and then reaching around from the plate to the back of the rotor with some BIG c-clamps. Then I just twisted the clamps evenly until the rotor popped forward. Good luck. 
Thread Starter
Pro
Joined: Oct 2006
Posts: 576
Likes: 0
From: Independence Mo.
Armed with a large hammer and alot of four letter words it has poped off now and starting to wire brush all that is needed. I hope the other 3 go alot easier than this. Thank You All 
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Front or rear? You need to hit them with some WD40 around the studs and a few carefuls shot with a rubber mallet. On the rears you have to be care because of the emergency brakes shoes on the inside of the rotor.
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Glad you got them off - sometimes all it takes is a big hammer.
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