2001 S40 Rusted brake disk removal

Post by **alschnertz** » 03 Nov 2014, 06:24

I'm in the middle of a front pad & rotor replacement on the '01 S40.

Struggled, but eventually got the rusty disk off the left side.

The right side disk is being stubborn. I first sprayed with PB Blaster; pounded around the hub portion with a hammer; tried threading bolts through the threaded holes that are in the disk (to facilitate easy removal, not!) but those stripped and lastly tried a large gear puller that grabbed from the outside of the disk. None of those worked.

I saw some youtube videos that used a bolt through the caliper mount holes to push the back side of the rotor. I may end up using that method, but am concerned about bending the ears that the caliper mounts to. Anyone ever use that method? How did it work?

The other method I was going to try is less conventional. Here's what I'm thinking...
Remove the wheel, reinstall the lug nuts all the way till they bottom out on the rotor and then back them off a half turn; lower the car so the brake disk rests on a block of wood; roll the car back and forth and hopefully the rusted bond will release. What do you think? Bad idea?

I've heard of something like this to release rusted rims and thought it may work for the rotor.

Livens · Post by **Livens** » 03 Nov 2014, 10:33

I've had stuck rotors on other cars and here is a trick that always works for me. Get a propane torch and heat up the hub section of the rotor, then give it a good whack with the biggest hammer you've got. I have a 5 lb. sledge that works great for this sort of thing.

Post by **alschnertz** » 03 Nov 2014, 15:19

You're right, and I forgot to mention that I did the heat too to no avail.
I'm a little reluctant to pound the heck out of it. I don't want to ruin anything else.
I guess it would be wise to remove the ABS sensor before pounding it.

For now, I still want to try rolling it on a block of wood.

instarx · Post by **instarx** » 04 Nov 2014, 03:40

Maybe this is a little obvious, but you did remove the wheel locator pin(s), right?

Post by **alschnertz** » 04 Nov 2014, 07:52

This '01 S40 does not have locating pins like a 700 or 850.
Maybe others did, but those are the only other two that I'm familiar with.

Obvious yes, but thanks for trying.

Livens · Post by **Livens** » 04 Nov 2014, 12:03

alschnertz wrote:You're right, and I forgot to mention that I did the heat too to no avail.
I'm a little reluctant to pound the heck out of it. I don't want to ruin anything else.
I guess it would be wise to remove the ABS sensor before pounding it.

For now, I still want to try rolling it on a block of wood.

I have 'heard' that you can crack the cage inside of CV joints by hitting them too hard straight on, but from the side or on the rotor edge you should be fine.

As a final resort... know anyone with an angle grinder

Good luck and let us know how you make out.

Post by **oragex** » 04 Nov 2014, 20:40

Get a piece of solid wood, and force it between the upper disk side and a part of the spindle. Hammer the wood downwards.

Post by **alschnertz** » 09 Nov 2014, 18:18

Well, rolling the disk on a block of wood did nothing.
So I resorted to using a couple of bolts through the caliper mounting holes.
It worked fine and I was done in a half hour.
Here's a youtube video of the procedure. It's not on a Volvo, but it worked the same.