Question about Ford Expedition

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How to remove a rusted rotor on a hub? i want to takethe hub off and get the rotor pressed.. any thoughts 99 ford Expedition front rotors..

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  • adam_gonz971 Oct 07, 2010

    i am trying to remove the rotor to replace it. so what you are saying is that the hub and rotor are one piece.. cause i went to the auto zone for the rotor and it is a singal pieces with out the hub.. i cant remove the rotor from the hub?? need help please...

  • adam_gonz971 Oct 07, 2010

    no it is a 4wd 5.4 and yes there is a dust cap on it i toke the dust cap off but didnt think of taken the hub off casue like i said i went to auto zone and they showed me a rotor with out the hub on. why would they show me the wrong one so my truck has the hub and rotor all in one assembly i will try that. do u know wht size nut holds on the hub??



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Are you talking about the front rotors? The hub and rotor are one assembly and do not seperate on that truck. If you need to replace one part, the replacement part will have the hub and rotor together.

Posted on Oct 07, 2010

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  • adam_gonz971 Oct 07, 2010

    i am trying to remove the rotor to replace it. so what you are saying is that the hub and rotor are one piece.. cause i went to the auto zone for the rotor and it is a singal pieces with out the hub.. i cant remove the rotor from the hub?? need help please...

  • razorneck Oct 07, 2010

    I am just assuming this is a 2 wheel drive truck with a 4.6L. And those use a hub/rotor assembly.
    Better yet, look at your old rotor. And the center of the hub. Is there a dust cap on that hub? If so, you can pry the dust cap off, remove the spindle nut insid ethere with all the grease around it and remove the outer wheel bearing. Now you can put thespindle nut back on (3-4 turns with your fingers only) and pull the hub/rotor off with a jerking motion catching the inner bearing on the spindle nut as you ****. This will pop the hub seal and the inner bearing out os the hub and leave it hanging on the spindle. What you are holding in your hands is the old hub/rotor assembly. Plus some old grease inside the hub. Take that to the parts store and tell them that is what you need.
    Be sure to get some bearing grease to repack the bearings and fillup the inside of the new hub before you assemble it all back together. You will pack your inner bearing first, drop it in the back side of the hub and gently tap the seal back in to retain the inner bearing. Now you can hang the rotor back on the spingle, insert the greased outer bearing and nut/washer, tighten until a slight drag is felt reinstall your grease cap and finish the brake job.

  • razorneck Oct 07, 2010

    4 Wheel drive changes things. This should have a locking hub. Forget all I told you before.
    I assumed you had a 2WD because it is far more common.
    Rust seized rotors can be stubborn. Take two of your lug nuts and thread them on two of the wheel studs a couple of turns. This will keep the old rotor from falling off when you knock it free. Now you will need to get a hammer. I use a 3lb. flat peen sledge. You need to take that hammer and strike the base of the rotor (the part of the rotor thatthe studs go through) in between the studs. Do not hit the studs and do not his the rotor where the pads contact it!
    I'm a lean 205lbs with about 8% body fat and I swing that 3lb. hammer hard. It sometimes takes a few hits in between different studs to knock it loose. Point being don't be afraid to swing it hard. It's okay to spill elbow grease all over the place when you're knocking these things loose.



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I have a 2004 Ford expedition I need to know how

The problem with these units is the Emergency brakes are inside of the rear rotors. This causes problems in several ways. The E. brake material can jam inside the rotor/drum and the E. brake needs to be fully retracted to give clearance to remove the rotor. Sometimes the rotor rusts to the axle hub.

Check the link behind the rotor. There are different styles and this pivot may need to be hit with something to drive it closed. Just because the brake cable is retracted does not mean the pivot is fully retracted.

For rust, sometimes it is necessary to put the trans in neutral and turn the axles at the same time you squirt oil in behind the wheel studs. By rotating the axle shaft and tapping the rotor, you force oil into the back surface of the rotor. A rotor puller may be necessary.

Oct 04, 2014 | 2004 Ford Expedition

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How to remove front brake rotors on Ford expedition 2003

Remove caliper and caliper bracket, some time the rotor will have two small metal clips remove them, also some times you have to used a hammer due to rust, rotor should slide off,

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Changing rotors and brakes on ford expedition 99

I also have a 1999 model. What parts you want to use really depends on how much money you can spend. You can have the rotors turned (recut) but it takes time and if you want to keep the vehicle; new rotors will start out with the same potential life. Recut rotors will be different thicknesses and thin rotors will fail more quickly. You could end up with 4 different thicknesses.

The old brake linings will show how the calipers are working. You want even wear. You can also have Emergency brakes linings inside the rear rotors. With ABS and Traction control the wheel sensors can be fouled with brake debris so it is important for the E brakes to be in good shape.

I prefer Ceramic pads. They cost more, but are more heat resistant for towing and do not show brake dust. At least put them in front as most of the wear is in front. There is also a COP car pad with also works well but shows dust as it wears.

Tips for removal- Rust can be a big problem. The rotors will swell around the hubs in back of the rotor. A Dremel or cold chisel is necessary to remove the rust on the hub. Plenty of Rust solvent is needed. Eye protection is a must. You will need to draw in the Caliper pistons so you should have a big C clamp (Big Lots store) and use an old lining pad to press the pistons back. Also remove the brake rmaster cylinder cap before pushing in brake pistons.

New hardware is recommended and lube the slides with high temperature grease. Thats about it. Good Luck to you.

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1 Answer

Taking off front rotors to replace them

The rotor are probably rusted to the hub.Try some pb blast and let the sit. If that doesn't work tru a big hammer. I had to remove the hubs and press the rotors off.

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1 Answer

How to replace 99 gmc 3/4 tom brake rotors

Removal & Installation
  1. Remove 2/3of the brake fluid from the master cylinder.
  2. Raise and support the vehicle.
  3. Remove the tire and wheel assembly.
  4. Remove the front wheel hub extension (dual wheel vehicles only).
    • Insert a drift or large screwdriver through the brake caliper into one of the brake rotor vanes in order to prevent the rotor from turning.
    • Mark the relationship of the front wheel hub extension to the hub
    • Remove the front wheel hub extension bolts
    • Remove the front wheel hub extension from the vehicle. It may be necessary to tap around the perimeter of the hub extension with a rubber mallet to loosen it from the hub
  5. Mark the relationship of the rotor to the hub.
  6. Remove the caliper and mounting bracket as an assembly.
  7. Hang the caliper and the mounting bracket assembly from the suspension using mechanics wire.
  8. Remove the rotor.
  9. If the rotor is difficult to remove due to corrosion in the hub area use the following procedure to remove the rotor (25 series only).
    • Clean all the surface areas and the threaded holes of contamination
    • Generously apply penetrating oil or the equivalent to the hub/rotor area
    • Insert (2) M10 x 1.5 bolts (jack screws) into the threaded holes of the rotor
    • Tighten both bolts evenly to force the rotor from the hub.
To install:
  1. Clean all rust and contaminants from the both side of the rotor and the hub flange.
    NOTE If the rotor was removed using the jack screw method you must ensure that the hub flange is free of nicks or marks caused by this procedure. Remove all raised nicks or marks before installing the rotor.

  2. Install the rotor.
  3. Install the caliper and the mounting bracket as an assembly.
  4. Install the tire and wheel assembly.
  5. Remove the safety stands.
  6. Lower the vehicle.

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1 Answer

How do I remove a front rotor from my 2004 4wd expedition?

remove the 2 bolts on the caliper. then there are 2 additional bolts that hold the caliper bracket to the steering knuckle, once you remove the bracket, the rotor should slide off. i have had to use lots of blaster and a sledge to remove them in pa. where i live due to the hub rusts to the rotors. hope this helped you

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3 Answers

I took the caliper off on the rear wheels and I am trying to get the rotors off. I am hitting the rotors but they are not coming off. I don't know if they are held by a bolt or just rusted on. It is a Ford...

I had the same problem with the fronts on my 2003 expedition. Assuming you took all the bolts/clips off that could be holding it then I think you have a rusted on problem that even wd40 wont help. Here is a link on how I removed my fronts 5 years ago when the truck was only a year old and the rotors were deeply scarred with the pads that ford first used back then that made the wheels get dirty from brake dust, look for orlandoguy in the postings. basically you use a circular saw with a metal cutting blade to put a weak spot the on the rotor by cutting a slot in the rotor and use a cold chisel and small 5 lb hammer to split it after, Once you crack the rotor you break the rust bond on the hub and it slides off. I wirebrushed the hubs after and used wheel bearing grease to put a thin film on that mating surface to make the next rotor replacement easier.

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If rust is problem in your area I would suggest (if you have the strength) to remove the knuckle with the rotor still on the hub assembly because F-150's and Expeditions are notorious for the rotors seizing and it's nearly impossible to remove them without damaging them

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How do I remove rear brake rotors on a 2004 Ford Expedition?

Remove the brake caliper bolts{2} and caliper.
soak the rotor around the hub with penetrant oil and knock off with large hammer, careful not to hit the wheel studs. These rotors corrode and rust on really bad. If you can loosen the self adjuster behind the backing plate for the parking brake shoes, this will help as they hang up on them too.

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They get rusted to the hub. Try heat and a large hammer.

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