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Rear brake rotors rusted on S60

I've changed Volvo brake rotors, front and rear, so I know the drill.

But, the rear rotors on my 2007 S60 won't budge. WD40. Whacked it silly with rubber mallet...nothing.

The splash flange behind the rotor which wraps around the front makes it impossible to use the caliper frame mount holes to insert a screw "jack".

I'm out of ideas. How do the pros extract a stuck rear rotor?








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    Rear brake rotors rusted on S60

    Of course, the retaining bolt must be removed, and the emergency brake must be OFF, before attempting to whack off the old rotor.

    I got the job done with a heavy steel hammer. I whacked the old rotor from different directions...perpendicular to the axle, face on towards the hub. You should see some rust dust falling out from these whacks.

    Finally, I whacked the exposed backside of the rotor (the sector where the caliper normally resides) while slowly rotating the rotor. After about 10-15 of these whacks, it broke loose.

    Before installing the new rotor, remember to spray it with brake cleaner and wipe it off, to remove the anti-oxidative coating.

    To fully compress the caliper to make room for the thickness of the new pads, I use a "C" clamp with the old brake pad still attached to the piston. Before doing this step, I withdraw 20 cc of brake fluid from the brake fluid reservoir, as compressing the piston will raise the level in the reservoir -- you don't want it to spill over.

    I only use authentic Volvo parts. The new rotors and pads are working great.

    Thanks to everyone who contributed to this thread.








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      Rear brake rotors rusted on S60

      Next time use a bigger hammer, and don't be so timid. :-)

      You didn't comment on condition of the e-brake shoes, which seem to have
      a habit of delaminating.

      Bill








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    Rear brake rotors rusted on S60

    Obviously, you removed the screw(s) that hold the rotor in place.

    I use a two pound sledge and bang all around the hat portion of the rotor.

    Heating the hat might help.

    If the hat is cast - lift the car up a bit with a bottle jack under the rotor hat and give the hat a great wack with a 10 or 15 pound rock breaking sledge that has one face narrowed to a sort of rounded point. Maybe you can crack the hat.

    I have my grandfather's rock hammer, and I can't imagine how he swung it all day.








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    Rear brake rotors rusted on S60

    Well, you can't hit it from the inside. I have an 8lb sledge hammer, solid steel. It came in handy when one of my front rotors froze.

    You don't care what it looks like, you have a new one. I first tried with a block of wood and a 1lb hammer, that was futile. After the 2X4 became toothpicks, I used just the hammer. Lots of dimples, no movement. The 8lb worked!
    --
    Keeping it running is better than buying new








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    Rear brake rotors rusted on S60

    "... Whacked it silly with rubber mallet...nothing...."

    Unless you're trying to save the rotors, whack them with a SOLID hammer. A rubber mallet doesn't apply the proper "jolt".
    --
    Current rides: 2005 Volvo S80 2.5T, 2003 Volvo V70 2.4NA, 1973 Volvo 1800ES (getting ever closer to road worthiness)








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      Rear brake rotors rusted on S60

      Thought of that, but it's a bit risky...what if the rotors don't yield to the steel hammer? Now they're gouged and stuck on.

      I was looking more for an "extractor" idea. Know of any?








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        Rear brake rotors rusted on S60

        Chris is right,

        Use a big hammer, even a sledge and it will come free, probably the brake shoes delaminated and are wedged in there, and another hint, don't use ordinary Chinese rotors from your local part stores, stick with OEM or find ATE (OEM) rotors.
        I found ATE rotors with a good price at AutohausAZ, They had the ATE pads, shoes and brake fluid too.

        Bill










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          Rear brake rotors rusted on S60

          Zimmermann makes an excellent rotor for volvo, called z-cast.
          --
          I'm stuck on Volvo and Volvo's stuck on me....when it comes to FWD I always listen to the "Oracle of Minnesota'







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