I'd like to put in a new cap and rotor, but the rotor seems really stuck on the shaft. This one's been on at least ten years. I don't want to damage anything by prying too hard. It has the red Bosch set-up. Any tips? Thanks!

Every time I buy a new (used) 240, I seem to run into this problem when I do the first tune-up (never a problem subsequently because I use antiseize when I put my rotors on).

Anyway, here's my foolproof (so far) method, which cannot damage the distributor or rotor, but will separate them: you need a weight (anything heavy, but I use my wife's 5-lb exercise dumb bell) and a long thin but very strong rope (about 4 ft, and I use a small sailboat's halyard) -- don't use nylon because it stretches, and you don't want the "springy" effect.

First tie the rope into a large loop, and then take a small portion of that large loop and wrap a couple of turns (almost a figure eight) around the two "ears" (the contact end and the counterweight end) of the rotor. Likewise wrap a few turns of the rope at the opposite end of the large loop around the weight you're using. Be sure to have about 18" or more of slack between the rotor and the weight, and have an equal length of rope on the two segments of those slack portions (you started with a loop, right?).

Now, give a very quick and forceful upward stroke holding the weight. Assuming your rope is strong (so it won't snap), the momentum of the weight and shock of the suddenly taught rope lifting the rotor will free the stuck rotor!

You have good info how to remove your stuck rotor, but I want to ask how is it you have had the same rotor on for 10 years? Is that "normal"? Maybe the fact that I change my rotor (and cap)once a year is AB-normal? Was the end of your rotor badly burned and the how were the contact points in the dist cap?

I have had occasion to remove the rotor and scrape the carbon off the tip on the cement floor and put it back on.. It works in a pinch.


(I do use just a touch of anti-sieze, btw.)

I squeeze the base of the rotor with vise grip pliers hard enough to get the rotor to fracture, and then it comes off. Use a wire brush on the the shaft or some emery cloth, to clean it up. If you use emery cloth be careful of where the grit goes. Use some silicone grease on the shaft when you install the new rotor.
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john

Big set of channel locks on it, and crack it, you're not going to reuse it and the breaking process is (imho) less stressful. Hose out the remnants. When you put the new rotor on put some kind of anti seize on it, or at least some silicone, spray to ward off moisture accumulation

I would put a rag under the rotor if you end up breaking it to remove it so as to keep all the resulting pieces out of distributor.

Randy

Big set of channel locks on it, and crack it, you're not going to reuse it and the breaking process is (imho) less stressful. Hose out the remnants. When you put the new rotor on put some kind of anti seize on it, or at least some silicone, spray to ward off moisture accumulation

pry it out with a screw driver. it doesn't matter if you smash it or crack as its diposable.

worst case hit it on top with a hammer to crack it

Thanks everyone. I'll try the rope underneath method and then I can always 'crumble' it off with channel locks if that doesn't work. I just didn't want to damage any bushings or internal mechanisms with too much force.

Glad I asked.

Steve

Hi,

In this thread there is a few rope methods that seem like good ideas.

http://www.brickboard.com/RWD/volvo/1270726/220/240/260/280/89_b230_distributor_rotor_stuck_need_tips_break_something.html

Hope that helps,

Travis

Just try to wiggle it back and forth it will eventually come off. Put an open end wrench under it and either tap or pry it out.
Dan