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Re: one rotor comes off the other is held on by the wheel...
Well, i assume you don't have an air hammer do you? if so, hit the rotor between the wheel studs. I assume you have at least a hammer? Start hitting the rotor between the wheel hubs. First the top half then the other, making sure not to hit the rotor where the brake pads ride. Oh, don't forget to spray around the hub with wd40
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It could be a bad wheel bearing, and if so it probably is the passenger side, but check them both sides. Raise both wheels off the ground, or one at a time, and rock the wheel back and forth and up and down. The side with the bad bearing will have a lot more play in it.
To replace, the wheel "hub" with sealed bearing inside is replaced. The hub is bolted to the wheel knuckle, which supports the hub, the CV joint and axle shaft, the brake caliper and rotor, and the wheel itself. If you are experienced at car repair and have the proper tools, you can do it yourself. At a shop, expect a 2-4 hour labor bill, maybe under 2 hours if everything comes off easily. The cost of the hub and sealed bearing is probably less than $100, although prices can vary greatly.
remove the wheel-remove the brake calliper-- the rotor will be held on by the wheel or will have counter sunk screws that you will have to remove. Check with the new rotor first as it may be a complete hub assembly in which case the whole hub has to come off or be replaced.
Remove wheel, brake caliper bracket, rotor, tie brake caliper up out of the way as to not put tension on the hose, remove hub bearing & assembly, yank c.v shaft out (just held in by clips) pop new shaft in securely, reassemble hub, brakes & wheel.
When you say no vacuum leaks, is this specific to the driver's side IWE ( Integrated Wheel End ) ?
Did you hook up the vent and vacuum line correctly ( not backwards ) ? - Use the passenger's side as a reference.
If you jack up the truck ( engine off ) and use a might vac ( or similar vacuum pump ) on the IWE directly, will it pull the IWE gear out ? This should do the trick, as long as the new IWE gear was installed correctly.
If not, I would check the driver's side IWE install against the service manual, to make sure it was installed correctly.
I have a 2004 Toyota Matrix with a vibration noise coming from the front end. The noise gets louder the faster you drive and is present even when you push in on the clutch and put it in neutral. If the driver jerks the wheel to the right when driving the noise stops for a second. The noise keep up at the same pitch if you **** the wheel to Left. If you think it's a wheel bearing, which side would you guess?
Section 04-01: Suspension and Wheel Hubs, Front
1996 Taurus, Sable Workshop Manual
REMOVAL AND INSTALLATION
Wheel Hub Bolt
Raise vehicle on hoist.
Remove wheel and tire assembly. Refer to Section 04-04 .
Remove disc brake caliper (2B120), and front disc brake rotor (1125). Refer to Section 06-03 .
Brake Shoe and Lining
Remove brake master cylinder filler cap (2162). Check fluid level in brake master cylinder reservoir (2K478). Remove brake fluid until brake master cylinder reservoir is half full. Discard removed fluid.
Raise vehicle on hoist. Refer to Section 00-02 .
Remove wheel and tire assembly from front disc brake rotor mounting face. Use care to avoid damage or interference with disc brake caliper (2B120), front disc brake rotor shield (2K004) or front wheel knuckle (3K185).
Remove rear brake pin retainers (2N386). ( I think it is a T 40 torx bit you need)
NOTE: It is not necessary to disconnect hydraulic connections.
Lift disc brake caliper from front disc brake caliper anchor plate (2B292) and front disc brake rotor (1125). Do not pry directly against metal caliper piston or damage will occur.
Position disc brake caliper out of the way and support with wire to avoid damaging the disc brake caliper and front brake hose (2078).
Remove outer brake shoe and lining (2001) assembly from front disc brake caliper anchor plate.
Remove inner brake shoe and lining assembly.
Position lug bolt (1107) to clear front wheel knuckle (3K185).
Remove lug bolt from wheel hub (1104).
Install lug bolt into wheel hub.
Using a lug nut (1012), seat wheel hub bolt into wheel hub.
Install front disc brake rotor and disc brake caliper. Refer to Section 06-03 .
Install wheel and tire assembly. Tighten lug nut to 115-142Nm (85-104 lb-ft).
If you are talking about the brake rotors, you do NOT remove the 30 mm nut. That nut just holds the axle shaft to the hub. Remove the caliper and the caliper bracket, the rotor should come off, you may have to tap the brake rotor to dislodge it from the center hub.