Removing Brake Rotor

How To Remove That Stubborn Break Rotor

Original Writeup By infidel

Many times the rotor will come right off by hitting on it with a soft hammer from behind while rotating it.
If it doesn't...

Break the big nut lose with the tires on the ground but leave it tight. Jack the side you are working on high to keep differential fluid from running out. Remove wheel and brake caliper. Caliper takes a 3/8" allan head.
Remove three of the four bolts that hold the unit bearing on from the back side, they take a 12 point socket. Leave the last bolt most of the way screwed out, wedge a socket with extension in-between the bolt and differential housing, start the engine and turn the steering wheel to pop the bearing off. You will hear it very clearly when it pops. Leaving the big nut tight prevents the bearing form busting apart.

During this process keep the axle in it's normal position by stuffing rags under the u-joint. This keeps the axle seal from deforming and possibly leaking.

When you have the rotor off pound the studs out with a copper or brass headed hammer or press.

Pound the studs into the new rotor using a drift then make sure they are pulled in tight by tightening down a lug nut with a pile of washers under it.

Coat the axle stub with anti-seize before putting the bearing/rotor back on so it comes off easy next time.

http://www.dieseltruckresource.com/pics/data/500/medium/25501removing_rotor.jpg

--Iker42 22:30, 19 January 2009 (EST)