The Best Way to Remove a Rusty Brake Rotor

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    Remove the Rotor

    • Loosen the wheel lugs and use a floor jack to lift the wheel assembly with the brake rotor you need to replace. Support the car on a jack stand and remove the tire. If you are removing a rear rotor, remove the wheel bearing and related hardware assembly and keep these components in a proper container away from dust and other contaminants.

      Detach the brake caliper from the rotor and secure the caliper to the suspension using a piece of wire (leaving the brake caliper hanging loose may damage the brake hose). Then remove the brake-caliper mounting bracket.

      Clean the wheel assembly with brake parts cleaner and a clean shop rag. Now try to remove the rotor by hand. If it seems stuck, use a rubber mallet to tap around the back of the rotor to break the grip from the axle hub on the rotor. If that does not work, use a puller of the appropriate size. You may be able to rent one from your local auto parts store, if you do not have one on hand.

    Check the Rotor

    • Inspect the condition of the rotor or take it to an auto shop for inspection, if you are planning to reinstall the same component. Check for maximum disc run-out and minimum thickness. You can find these specifications in your vehicle service manual. Also, check the rotor for cracks, scores or heat checks, which can lead to brake vibration. Have the auto shop resurface the rotor or replace it with a new one if necessary.

    Reinstall the Rotor

    • If you are replacing a rear rotor, inspect the wheel bearing and race. If you see signs of damage or corrosion, replace it. Pack the wheel bearing or the new unit with high temperature grease. When reinstalling the rotor and wheel assembly, clean the rotor surface of any grease spots using the brake parts cleaner. Grease will burn and harden on the friction surface of the rotor and cause brake squeak. Grease on the lining surface of the brake pads will cause the brakes to grab, making it difficult to stop slowly or veer the car to one side when applied.

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