After experiencing vibration while braking, I am trying to remove the front brake rotors from a 2002 Ford Escort sedan in order to replace them. After removing the calipers, I can't get the rotors off ! I have tried hitting them with a 3 lbs. sledge hammer and sprayed on 2 cans of rust remover (which I let soak in overnight). They still won't move. It appears that the rotors are fused or rusted to the plate containing the lug bolts. Is there any way to break them loose ?
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Re: 2002 Ford Escort front brake rotors - removal
The first thing i will recomend you, is ti buy the new rotors first,
sisnce you did not mention if you allready have the new ones
and see if they are slide out type rotorss or one piece rotor assy
with the lugn nuts, sometimes they just slide out but sometimes you need to remove the center big nut in order to remove them.
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IT appears that only half of the master cylinder has bled properly. Try loosing the pipe nuts at the m/cyl and gently pump the pedal until you get fluid out of both lines. Then re-bleed the system starting at the longest line first ending at the shortest. Some master cylinders have a plunger fitted in the middle of the cylinder and this is there to still have brakes if a line fails. It may be necessary to remove it an plug the hole temporarily while you bleed the system as to stops one piston in the cylinder from moving and allowing proper bleeding
I believe I would check the rear Brakes. Your truck most likely has rear disc brakes. and most likely has an automatic transmission. Which means you never or rarely use your parking brake. I see it all the time. parking brake which is a drum brake under/inside and part of the rear rotor. It could also be a rear brake issue.Remove the rear tire, and look over the brake rotor and the pads. If everything looks ok there (rotor is smooth looking on the inner and outer face. they are not rusted and pitted. or gouged) pad has brake materiel of at least 1/8". if that looks ok then remove the caliper and look at the parking brake shoes and hardware. i see a lot of the shoes brake material comes loose from the backing. which will cause noise, vibration, sometimes wheel lock up.
I would check the rear brakes drums, they may need to be turned. The front rotors may have warped again, with turning the rotors, it removes metal from the rotor which leaves the rotor with less metal to dissipate heat, and the rotor will warp again when they get hot.
1) Remove tires
2) Remove 2 bolts that hold on the caliper (+ brake pads).
3) Remove hub grease cap (should just pop off)
4) Once the cap is removed, you'll see a large nut on the shaft with a pin through it. Remove pin and nut... the rotor will come off along with front bearing.
Section 06-03: Brakes, Front Disc
1999 Taurus/Sable Workshop Manual
REMOVAL AND INSTALLATION
Procedure revision date:
Raise vehicle on hoist.
Remove wheel and tire assembly. Be careful to avoid damage or interference
with caliper bleeder screw fitting and front disc brake rotor shield (2K004).
front disc brake rotor (1125) and disc brake caliper (2B120) assembly in such a
way as to prevent deformation of front disc brake rotor , and nicking,
scratching or contamination of brake linings/rotor surfaces. NOTE: To prevent damage, do not allow disc brake caliper to hang by the
front brake hose (2078) .
Remove caliper anchor plate bolts and discard. Position disc brake caliper
out of the way. Prevent separation of caliper housing from anchor bracket
because contamination of guide pin journals can occur.
NOTE: If excessive force must be used during front disc brake rotor
removal, the front disc brake rotor should be checked for runout prior to
If additional force is required to remove front disc brake rotor , apply Rust
Penetrant and Inhibitor F2AZ-19A501-A or equivalent meeting Ford specification
ESR-M99C56-A on front and rear rotor/hub mating surfaces. First, strike front
disc brake rotor between lug bolts (1107) with a plastic hammer. If this does
not work, attach 2-3 Jaw Puller 205-D027 (D80L-1013-A) or equivalent and remove
front disc brake rotor . Remove front disc brake rotor from wheel hub (1104)
assembly by pulling it off the lug bolts.
If original front disc brake rotor is being installed, make sure rotor
braking and mounting surfaces are clean.
to clean rust and foreign material from rotor and hub mounting faces when
installing new or old front disc brake rotors will result in high rotor runout,
which will speed up the development of brake roughness shudder
Apply a small amount of Silicone Brake Caliper Grease and Dielectric Compound
D7AZ-19A331-A or equivalent meeting Ford specification ESE-M1C171-A to pilot
diameter of front disc brake rotor.
Install front disc brake rotor on wheel hub assembly.
Install disc brake caliper and new caliper anchor bracket bolts on front disc
brake rotor . Tighten caliper anchor bracket bolts to 88-118 Nm (65-87 lb-ft).
to tighten lug nuts (1012) in a star pattern may result in high rotor runout,
which will speed up the development of brake roughness, shudder and
Install wheel and tire assembly on vehicle. Tighten lug nuts to 115-142 Nm
(85-104 lb-ft) using Rotunda Accutorq® Lug Nut Socket 164-R0303 or equivalent on
a 1/2 inch air impact wrench, or use a torque wrench.
Pump brake pedal prior to moving vehicle to position brake linings.