Reasons Why the Rotor Won't Come Off:
* Rust and Corrosion: This is the most common culprit. Rust builds up between the rotor and the hub, effectively welding them together.
* Seized Bearing: The wheel bearing might be seized, preventing the rotor from spinning freely and coming off.
* Damaged Rotor or Hub: A warped rotor or a damaged hub flange can prevent proper separation.
* Incorrect Removal Technique: Using the wrong tools or applying force in the wrong direction can damage components and make removal harder.
* Improperly Removed Lug Nuts: If the lug nuts weren't completely removed before attempting rotor removal, they may be interfering.
How to Remove a Stuck Rotor:
1. Preparation:
* Safety First: Use jack stands to securely support the vehicle. Never work under a vehicle supported only by a jack. Wear safety glasses.
* Tools: You'll need a lug wrench, a hammer, a punch (preferably a brass or plastic one to avoid damaging the rotor), penetrating oil (like PB Blaster), and possibly a rotor puller (available at auto parts stores).
2. Loosen and Remove the Wheel:
* Remove the wheel: Loosen and remove the lug nuts completely *before* jacking up the car.
* Clean the area: Thoroughly clean the area around the rotor and hub to allow better access and observation.
3. Penetrating Oil:
* Apply liberally: Generously apply penetrating oil to the area where the rotor and hub meet. Let it sit for at least 30 minutes, ideally longer (even overnight). This helps break down rust and corrosion. Reapply as needed.
4. Removal Attempts:
* Gentle tapping: After the penetrating oil has soaked in, use a hammer and a punch (brass or plastic is ideal) to gently tap around the circumference of the rotor hat, working your way around. Tap *gently*; aggressive force can damage the rotor or hub.
* Rotor puller: If tapping doesn't work, a rotor puller is the next best option. These tools are designed to grip the rotor and pull it away from the hub. Follow the instructions included with the puller carefully.
* Last Resort (with caution): If all else fails, you might try using a slide hammer or a larger hammer with careful, controlled blows. However, this carries a greater risk of damage.
5. Inspect and Replace:
* Inspect the hub and rotor: Once removed, carefully inspect both the hub and the rotor for damage. Replace either or both if they're damaged.
* Clean the hub: Clean the hub thoroughly of any rust or debris before installing the new rotor.
If you're uncomfortable working on your car yourself, take it to a qualified mechanic. Improper removal can lead to damage that will cost you more in the long run. This is especially true if you damage the wheel bearings.
