1. Preparation:
* Safety First: Use jack stands to securely lift the vehicle. Never work under a car supported only by a jack. Wear safety glasses.
* Tools: You'll need a wheel wrench, a hammer, a large flat-head screwdriver (or a rotor removal tool – highly recommended), possibly a penetrating lubricant (like PB Blaster), and potentially a slide hammer.
* Wheel Removal: Remove the wheel and tire.
2. Rust and Corrosion is the Enemy:
* Penetrating Lubricant: This is your best friend. Liberally spray penetrating lubricant (PB Blaster is a popular choice) around the rotor's mounting surface where it contacts the hub. Let it sit for at least 15-30 minutes (longer is better), allowing it to work its way into any rust or corrosion. You may need to reapply it several times.
3. Attempting Removal:
* Gentle Persuasion: Try using a rubber mallet and gently tapping the rotor around its circumference. This might be enough to break the rust bond. Avoid striking the rotor directly in the center, as this could damage it.
* Flathead Screwdriver Method: Carefully place the flathead screwdriver between the rotor and hub, using it as a lever. Gently pry. If the rotor doesn't budge easily, stop and reapply penetrating lubricant. Be very cautious not to damage the hub. A dedicated rotor removal tool is far less likely to damage the hub.
* Rotor Removal Tool: If you have a rotor removal tool (highly recommended), this will make the process much easier and safer. These tools typically have a screw-like mechanism that exerts force on the rotor, separating it from the hub. Follow the manufacturer's instructions for its use.
* Slide Hammer (Last Resort): If other methods fail, you might try a slide hammer. Carefully attach the slide hammer's claw to the rotor's center hole, and gently pull. Be extremely careful not to damage the hub or wheel studs. Overly aggressive use could cause serious damage.
4. If All Else Fails:
* Professional Help: If you've tried all of the above and the rotor is still stubbornly stuck, it might be time to seek professional help from a mechanic. They have specialized tools and experience to handle this type of situation. Continuing to force it could damage the hub, requiring a more extensive and expensive repair.
Important Considerations:
* Hub Damage: Be extremely careful not to damage the hub during this process. A damaged hub is a much more serious and expensive problem than a stuck rotor.
* Caliper Removal: While not strictly necessary for rotor removal on many cars, some mechanics prefer removing the caliper to give them better access and leverage. However, if you are not comfortable working with brake calipers, don't attempt this.
Remember, patience and careful application of force are key. Rushing the process can easily lead to damage. If you're unsure about any step, it's always best to consult a professional mechanic.
