How to Remove Stubborn Brake Rotors

A stubborn brake rotor can be a challenge to remove. Changing the disc brakes on a vehicle is relatively straightforward. You remove the wheel, pull the caliper off and then slide the rotor off the wheel hub. The plan works just fine until you run into a stubborn rooter that has seized on the wheel hub. This quickly brings a 20-minute job to a screeching halt. There are a few things you can do to get that rotor off the wheel hub
Procedure:
1. Inspect the wheel studs on the axle. The rotor slides over the wheel studs, and a small splined washer holds the rotor onto the studs. This is often overlooked when doing a brake job, and with the splined washer in place, the rotor is almost impossible to get off. If you locate the splined washer still on one of the wheel studs, remove it by prying it off with a small flat-head screwdriver.
2. Spray the wheel studs and the axle hub with liquid rust remover, such as Liquid Wrench, WD-40 or Rust Breaker. Use a liberal amount. Make sure you spray the axle hub on the back of the rotor. Apply more spray every 10 minutes and allow the liquid rust remover at least 30 minutes to penetrate.
3. Pound the back of the rotor with a rubber mallet if you plan to reuse the rotor. If you are going to use a new rotor, use a 5-pound sledgehammer. Rotate the rotor as you strike the back of it until you break the rust free and the rotor pops off the axle hub.