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Removing Rusted Stuck Brake Rotors
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A common problem with Expeditions or Ford F-150s is the Brake Rotors become stuck or rusted (more like welded) on the hub. So we did some research on forums and came up with several different methods to get them off. To summarize there is heat, jacking them with screws, banging the crap out of them, and then a whole series of others that include everything from acetylene torches to dynamite.
MT got the driver's side off by using the jacking method, but the passenger side turned out to be a little trickier. Despite this, the best method still remains the jacking method to begin with. I’m not going to steal the glory either, I got the idea from “sanman1969” in a forum post where he describes it better than I can; you will find here
I do have one warning; the jacking method involves putting screws through the caliper mounts to create outward pressure on the disc. Just be careful, with enough force anything will bend, even these substantial “ears” on the caliper mount. You can however bend them back without damaging them; you just have to make sure you get them aligned properly by checking the fit once the calipers are back on.
The other thing to keep in mind is that you WILL NOT be reusing these rotors again. In our case we decided to replace them while replacing the upper and lower control arms. My point being if they are stuck that bad that you need to hammer them or jack them with screws to remove them, they are done! In this situation both sides ended up cracking right through before they finally came off. The difference was that the passenger side required a bit off heating with a bernzomatic before it hammered loose.
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