To avoid these ads, REGISTER NOW!

Best tool to pull a rotor without damage

NorthJersey

Member
Joined
Jan 25, 2014
Messages
7
What is the best tool to remove a stuck rotor while preserving the rotor? My nice US-made rear rotor (extremely rare NOS find) on a Chevy Express is fused to the hub. I want to remove it to access the parking brake shoe.

I have a rotor puller and a Snap-on air hammer. Do you think the puller will damage the rotor? The last time I used the puller, I’d already beaten the rotor to pieces with a sledgehammer, so I wasn’t paying attention to additional damage.

Would an air hammer alone (used only on the mating surfaces) be best, or could I safely use the puller in conjunction with the hammer? Would a little MAPP in the mix exacerbate any rotor damage?

Please forgive the novice questions.
 
To avoid these ads, REGISTER NOW!

rust in the eye

Well-known member
Joined
Oct 2, 2017
Messages
2,793
Location
Chicagoland
Be careful if using heat as the bearings and seals don't like it.
Cleaning the exposed bit of the hub with a wire wheel will make final extraction easier once you break the bond.
Penetrating oil, get in around the lug openings as well as the hub, and patience help, brute force remains your best friend. If you have a puller don't rely on only the force of the puller. Keep hammering away to shock the bonded parts. Once you get any movement you're home free,just patience from then on.
OH! anti-seize paste on the hub when re-assembling. Save the next guy(perhaps you) the headache.
 

swsman

Well-known member
Joined
May 5, 2021
Messages
574
Location
Earthbound
Penetrating oil, move the air hammer and attack from multiple positions.

In the past I would grab a block of wood to protect the surface and tap around with the hammer - from the front and from the back.
 

cgrutt

Well-known member
Joined
Mar 4, 2016
Messages
8,302
I'm not a pro so take this for whats it's worth. Had a very difficult rear rotor on an older F150 that i had almost given up on. As stated above penetrant oil in stud holes and around center hub. Give it a few hours or overnight to work. Hit between studs with a dead blow. Heat same area with propane/mapp torch. Keep working it with hammer. I wound up buying a large puller put some tension on it and kept working it with hammer. It eventually gave up the battle. Be sure to put one or more lug nuts loosely on studs to keep the rotor from flying off when it breaks free.

Oh be sure to release emergency brake and that there are no screws or clips retaining rotor to hub. Not familiar with Chevy Express.

I forget which hub puller I bought but it's pretty substantial. May be the Astro or OTC. I'm assuming you're in Northern NJ by your username I'm in Rockland county right across border from Bergen Cty. LMK if you need the puller happy to help if I can.
 

L.Cheapo

Well-known member
Joined
Oct 23, 2014
Messages
5,946
Also, you can use the air hammer on the rotor near the wheel studs. That will help.
That's what I do. Air hammer with flat bit between the studs. The Snap On should hit hard enough to get it done. Always does for me. I wouldn't use a puller on a rotor I wanted to use again.

A GM part made in USA? That should be in a museum! :ROFLMAO:
 

rlitman

Well-known member
Joined
Oct 18, 2010
Messages
24,617
Location
Long Island
Be careful if using heat as the bearings and seals don't like it...
You do know brakes get quite hot. It would take a LOT of torching on the hat to heat the bearings more than the brakes do.

But anyway, the advice I've gotten here is to loosen the lug nuts a turn and go for a figure 8's around a parking lot.
 

Kscardsfan

Well-known member
Joined
Apr 28, 2020
Messages
1,650
Location
The Little Apple
You do know brakes get quite hot. It would take a LOT of torching on the hat to heat the bearings more than the brakes do.

But anyway, the advice I've gotten here is to loosen the lug nuts a turn and go for a figure 8's around a parking lot.
Guilty of that method myself.
 

2ndGearRubber

Well-known member
Joined
Mar 24, 2014
Messages
14,185
Location
Pittsburgh
Air hammer around the hat area where it contact the hub, hope. If that doesn't work you need to add a puller. Screw the lug nuts a few threads so when it goes POP it doesn't go flying. Rattle it with the air hammer with the puller tension applied. Hope.


Be aware that rotors exist which are entirely impossible to remove and salvage. Enough pressure on the puller will eventually break sections of the braking surface off. If you're really unlucky you can have just the center section frozen with all of the braking surface broken off. Usually those GMs are mostly stuck on the parking brake shoes. It's been a good while since I found a parking brake adjuster I could both reach and was not rusted sold. If you can back it down, do so. Be aware even with the adjuster 100% collapsed the rust ridge on the rotor can be large enough the rotor still cannot slip off. As soon as the rotor moves hose down the parking brake area with penetrating oil to help the rotor slide over the shoes. If you're lucky you can have the friction material break off the shoes which really speeds up the process.


You do know brakes get quite hot. It would take a LOT of torching on the hat to heat the bearings more than the brakes do.

But anyway, the advice I've gotten here is to loosen the lug nuts a turn and go for a figure 8's around a parking lot.

My man I'm going to have that rotor hat liquifying. LOL

A little plumbing torch of course wouldn't hurt it, and also probably not do anything, although I've cut rotors off hubs before with an oxygen/propane torch.
 

Steve_P

Well-known member
Joined
Sep 15, 2010
Messages
5,185
If you pull the caliper, can you push against the rotor with a bolt and nut you insert into the caliper bracket? I don't have a picture, but a spare bolt and nut, diameter of the bolt smaller than the caliper bolt and it goes into the threaded/thru hole on the bracket. (edit) Nut is on the outside of the caliper bracket. One wrench on the nut, one you "loosen" the bolt with until the bolt head hits the rotor. Turn a bit. Back off. Rotate rotor 90*. Repeat.... It's a slow process but it's worked for me when big plastic hammers and the air hammer wouldn't.
 

L.Cheapo

Well-known member
Joined
Oct 23, 2014
Messages
5,946
If you pull the caliper, can you push against the rotor with a bolt and nut you insert into the caliper bracket? I don't have a picture, but a spare bolt and nut, diameter of the bolt smaller than the caliper bolt and it goes into the threaded/thru hole on the bracket. (edit) Nut is on the outside of the caliper bracket. One wrench on the nut, one you "loosen" the bolt with until the bolt head hits the rotor. Turn a bit. Back off. Rotate rotor 90*. Repeat.... It's a slow process but it's worked for me when big plastic hammers and the air hammer wouldn't.
That can result in breaking the caliper mount ears off the knuckle. And ding the surface of the rotor.
 

rlitman

Well-known member
Joined
Oct 18, 2010
Messages
24,617
Location
Long Island
If you pull the caliper, can you push against the rotor with a bolt and nut you insert into the caliper bracket?...
I wouldn't do that. It's even more likely to break something than a puller, which at least pulls straight off. Pushing from the ears would push off to one side only.

This is why lots of rotors have drilled and tapped holes that you can run bolts into. A pair of bolts screwed through the rotor at least gives you even (straight out) pushing against the hub, in a place that's least likely to do damage. But these holes strip easily.

...A little plumbing torch of course wouldn't hurt it, and also probably not do anything, although I've cut rotors off hubs before with an oxygen/propane torch.
Heat will expand it, but a plumbing torch is so weak that it's more likely to warm up the hub at the same speed as the rotor, so that doesn't buy you much. I'd use my oxy-acetylene cutting torch. The six tiny pre-heat flames make a fantastic miniature right-angle rosebud torch. Lots of concentrated heat. Enough to start seeing shades of color as you go around the circle for say 15 seconds, and a high enough temperature to get the rotor nice and hot before that transfers to the hub. Just keep your fingers off the lever. LOL

If you do go the torch route, setup a puller and pull on it gently enough that there's no risk of breaking anything. Having some pressure on it while you're heating it can make a big difference. Often the first indication of it working will be some noise as it starts to move, and you're not going to get that without the puller.
 

Steve_P

Well-known member
Joined
Sep 15, 2010
Messages
5,185
That can result in breaking the caliper mount ears off the knuckle. And ding the surface of the rotor.

Sure. You've got to use common sense. It's a last resort method, as I said. It's worked for me multiple times. I sand the head of the bolt smooth to prevent marking the rotor.
 

whitesco

Well-known member
Joined
Aug 1, 2022
Messages
399
Location
Pittsburgh, PA (ish)
I’ve done almost all of the above and also a slide hammer; I eventually bought one of these because all our cars now have rotors too large for 2 or 3 arm pullers (Mac is rebranded OTC which can be had for less):


One thing to be sure of on the rears is that the parking brake is fully retracted. I have a “friend” who has struggled mightily a time or two before realizing that they weren’t 100% clear. 😁
 
OP
N

NorthJersey

Member
Joined
Jan 25, 2014
Messages
7
Be careful if using heat as the bearings and seals don't like it.
Cleaning the exposed bit of the hub with a wire wheel will make final extraction easier once you break the bond.
Penetrating oil, get in around the lug openings as well as the hub, and patience help, brute force remains your best friend. If you have a puller don't rely on only the force of the puller. Keep hammering away to shock the bonded parts. Once you get any movement you're home free,just patience from then on.
OH! anti-seize paste on the hub when re-assembling. Save the next guy(perhaps you) the headache.
Wow! Thanks for all the feedback! I must not be getting e-mail notifications.

I usually anti-seize everything, and this one has been off fairly recently. I’ll report back on what I find when I get it off. I am most certainly the “next guy.” 😆
Try a big plastic dead blow hammer. Probably pop right off.
I don’t have one, but in my area, I find a 16-lb sledge usually won’t budge them easily if at all.
I'm not a pro so take this for whats it's worth. Had a very difficult rear rotor on an older F150 that i had almost given up on. As stated above penetrant oil in stud holes and around center hub. Give it a few hours or overnight to work. Hit between studs with a dead blow. Heat same area with propane/mapp torch. Keep working it with hammer. I wound up buying a large puller put some tension on it and kept working it with hammer. It eventually gave up the battle. Be sure to put one or more lug nuts loosely on studs to keep the rotor from flying off when it breaks free.

Oh be sure to release emergency brake and that there are no screws or clips retaining rotor to hub. Not familiar with Chevy Express.

I forget which hub puller I bought but it's pretty substantial. May be the Astro or OTC. I'm assuming you're in Northern NJ by your username I'm in Rockland county right across border from Bergen Cty. LMK if you need the puller happy to help if I can.
I appreciate the offer! I actually bought a two-arm puller when I was replacing a hub and I couldn’t separate the front rotor.
That's what I do. Air hammer with flat bit between the studs. The Snap On should hit hard enough to get it done. Always does for me. I wouldn't use a puller on a rotor I wanted to use again.

A GM part made in USA? That should be in a museum! :ROFLMAO:
It is as actually an Akebono. Haven’t been able to find another since. I can get EBC front rotors, but Mexico (AC Delco) is usually the best I can find for the rears.
Not sure if there's access on that model but sometimes it helps to back the parking shoes off before trying to get the rotor off
My reason for getting in there is to tighten the parking brake. It’s not really accessible from tbe back side.

Air hammer around the hat area where it contact the hub, hope. If that doesn't work you need to add a puller. Screw the lug nuts a few threads so when it goes POP it doesn't go flying. Rattle it with the air hammer with the puller tension applied. Hope.


Be aware that rotors exist which are entirely impossible to remove and salvage. Enough pressure on the puller will eventually break sections of the braking surface off. If you're really unlucky you can have just the center section frozen with all of the braking surface broken off. Usually those GMs are mostly stuck on the parking brake shoes. It's been a good while since I found a parking brake adjuster I could both reach and was not rusted sold. If you can back it down, do so. Be aware even with the adjuster 100% collapsed the rust ridge on the rotor can be large enough the rotor still cannot slip off. As soon as the rotor moves hose down the parking brake area with penetrating oil to help the rotor slide over the shoes. If you're lucky you can have the friction material break off the shoes which really speeds up the process.

My man I'm going to have that rotor hat liquifying. LOL

A little plumbing torch of course wouldn't hurt it, and also probably not do anything, although I've cut rotors off hubs before with an oxygen/propane torch.

The hat area isn’t really rusty, and I’m actually getting in there to tighten up the parking brake. I think it’s just salt-seized to the hub. I may have rushed last time and failed to use anti-seize. We’ll see soon!

If you pull the caliper, can you push against the rotor with a bolt and nut you insert into the caliper bracket? I don't have a picture, but a spare bolt and nut, diameter of the bolt smaller than the caliper bolt and it goes into the threaded/thru hole on the bracket. (edit) Nut is on the outside of the caliper bracket. One wrench on the nut, one you "loosen" the bolt with until the bolt head hits the rotor. Turn a bit. Back off. Rotate rotor 90*. Repeat.... It's a slow process but it's worked for me when big plastic hammers and the air hammer wouldn't.
I’m hoping the extra punch from the 3050 hammer will do it. I’m afraid the above method would cause more rotor damage than the two-arm puller.
 
To avoid these ads, REGISTER NOW!

racer1735

Well-known member
Joined
Aug 23, 2010
Messages
128
Location
Canyon, TX
Take note that some rotors have a small set screw holding them in place, in addition to the studs (Porsche is guilty of this. Don't know that GM does).
 
OP
N

NorthJersey

Member
Joined
Jan 25, 2014
Messages
7
Take note that some rotors have a small set screw holding them in place, in addition to the studs (Porsche is guilty of this. Don't know that GM does).
The Express rotors are secured solely by the wheels and lug nuts. Some GM vehicles use fasteners to secure the rotor directly, but not a set screw as far as I know. I have a GMC Yukon with large torx head screws that secure the rotors.
 

rooster59

Well-known member
Joined
Nov 16, 2014
Messages
961
Location
Land of the Pines
Well, if you are feeling adventurous-

Make sure there are no screws holding the rotor on. penetrating oil at the base of wheel studs, taps with a hammer in between the studs for a bit. Put the wheel back on, nuts threaded on all the way, then back off say ½ turn. Start, then back up at say 5 mph (?), slam on the brakes. Foreword same, slam on brakes. May need repeat.
 

iflyatiger

Well-known member
Joined
Jun 24, 2013
Messages
69
I’m far from an expert but I just went through this with a rear rotor on my Lexus suv. It would not budge off the hub until I got the right size bolts (8mm for Lexus / Toyota) that threaded into the threaded holes on the face of the rotor. This made it easy to feed the bolts in which pushes the rotor away from the hub. Also the parking brake shoes also held up the rotor from coming off the last bit.

Good luck
 

rlitman

Well-known member
Joined
Oct 18, 2010
Messages
24,617
Location
Long Island
You couldn't pay me enough to press against the end of the half axle in such a way that risks mushrooming it. Maybe I'm just being paranoid, but that seems like too much of a possibility of *********** into a nightmare.

I’m far from an expert but I just went through this with a rear rotor on my Lexus suv. It would not budge off the hub until I got the right size bolts (8mm for Lexus / Toyota) that threaded into the threaded holes on the face of the rotor. This made it easy to feed the bolts in which pushes the rotor away from the hub. Also the parking brake shoes also held up the rotor from coming off the last bit.

Good luck
+1, IF the rotor is drilled and tapped. Be sure to use at least 10.9 (equivalent to grade 8), or even 12.9 if you can find it, and grease the threads.
 

Wamsutta

Well-known member
Joined
Jan 8, 2014
Messages
10,879
Location
Amarillo, Texas
You couldn't pay me enough to press against the end of the half axle in such a way that risks mushrooming it. Maybe I'm just being paranoid, but that seems like too much of a possibility of *********** into a nightmare.
The main thing is to make sure you're not standing in front of the rotor as the puller has full tension on it.

Tap Tap Tap and the rotor goes flying off.
 

jsaw

Well-known member
Joined
Oct 11, 2008
Messages
1,788
Location
Geneva, N.Y.
You couldn't pay me enough to press against the end of the half axle in such a way that risks mushrooming it. Maybe I'm just being paranoid, but that seems like too much of a possibility of *********** into a nightmare.
Only time I ever had an issue was on a Mercedes Sprinter. They use a hollow axle that has a soft plug that if You push on it will be pressed out.
All other axles I have done all had a center that would mate to the adapter on the puller screw and have no problem at all
 

NHtoolguy

Well-known member
Joined
Mar 4, 2018
Messages
328
Location
Gilford, NH
You do know brakes get quite hot. It would take a LOT of torching on the hat to heat the bearings more than the brakes do.

But anyway, the advice I've gotten here is to loosen the lug nuts a turn and go for a figure 8's around a parking lot.
I have had good success loosening stuck brake drums and rotors with an oxy-acetylene torch. Just a few seconds of heat applied to the center of the assembly, around the studs. The sudden thermal expansion shears the rust bond. As you say, it takes a lot of heat to damage a seal or bearing.
 

gba2331

Well-known member
Joined
Sep 22, 2021
Messages
772
Not sure if there's access on that model but sometimes it helps to back the parking shoes off before trying to get the rotor off

My reason for getting in there is to tighten the parking brake. It’s not really accessible from tbe back side.

I had a similar situation where nothing worked until I finally figured out that the shoes were getting caught on the edge of rust that has built up on the drum area. Backing off the shoes a lot then allowed me to pull the rotors with a puller. Even thought the shoes may not be gripping, they could still be expanded enough to catch on the edge. Good luck!
 

pbon

Well-known member
Joined
May 14, 2017
Messages
3,498
I usually have to use a mini sledge to whack a block of wood on the rotor surface, and rotate the rotor around and repeat in multiple locations. This with the caliper removed. I put anti seize on the hub surface on cars but 10 years and 10 winters later it probably isn’t helping. I just whacked one such rotor off yesterday.
 

NYBODYMAN

Well-known member
Joined
Sep 10, 2013
Messages
4,858
Location
NY
If a torch/MAPP gas worries you, try an induction heater on the hat area.
 

3baygarage

Well-known member
Joined
Sep 1, 2013
Messages
11,963
Location
SW Florida/from Buffalo,NY
The main thing is to make sure you're not standing in front of the rotor as the puller has full tension on it.

Tap Tap Tap and the rotor goes flying off.
This happened to me using the Proto two jaw and 16” long 1/2” ratchet. I went to give the final cranks and the rotor popped with such force that everything flew apart. The puller hit the gas meter several feet away on the house. The neighbor came running over to check on me because it was so loud.
 

3baygarage

Well-known member
Joined
Sep 1, 2013
Messages
11,963
Location
SW Florida/from Buffalo,NY
You couldn't pay me enough to press against the end of the half axle in such a way that risks mushrooming it. Maybe I'm just being paranoid, but that seems like too much of a possibility of *********** into a nightmare.


+1, IF the rotor is drilled and tapped. Be sure to use at least 10.9 (equivalent to grade 8), or even 12.9 if you can find it, and grease the threads.
I can’t see a pressure screw mushrooming the shaft before the rust bond breaks. Push pull vs hammer blows mushrooming the end of something.

I did have one rotor crack at the center using the puller method.
 
To avoid these ads, REGISTER NOW!
Top Bottom