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How To Remove A Stuck Rotor (Step-by-Step Guide)

October 15, 2021

If you’re looking to install some fresh brake pads or replace a faulty wheel bearing, you may have run into some difficulty when removing your brake rotor. 

Don’t panic. 
In this article, we’ll explain how to remove a stuck rotor and how to prevent it from happening again in the future. 

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Let’s dive in.

How To Remove A Stuck Rotor (Step-by-Step Guide)

Removing stubborn rotors can be an uphill battle if there’s a lot of corrosion and rust. However, with some luck, a bit of hammering in specific locations will be enough to pry the two pieces free. 

Follow these six steps to unstick your brake rotor: 

  1. Remove The Brake Caliper From The Bracket
  2. Remove The Caliper Plate
  3. Temporarily Reattach The Lug Nuts
  4. Remove The Rust
  5. Grab Some Extra Equipment
  6. Insert The Bolts Into The Threaded Holes At The Back Of The Rotor

Before we get started, it’s important to point out that if you notice rust on certain components like your brake pads and shoes, have them replaced immediately. Rust can get between the braking plate friction material and cause brake failure.

Note: This job can take several hours and requires some specialist tools, like a propane torch or acetylene torch and a rotor puller, depending on the level of rust and corrosion present. Additionally, if you’re working on a rear rotor, ensure the parking brake isn’t engaged. 

It’s also great if you have some technical know-how to avoid damaging other brake components. As a result, it may be better to let professional mechanics handle the task for you. 

With that said, once you have the car jacked up and the wheel removed, you can follow these steps to dislodge your stubborn rotors: 

Step 1: Remove The Brake Caliper From The Bracket

There should be two rotor bolts, one located near the top of the caliper bracket, and the other closer to the bottom. This will loosen the caliper and provide access to the brake pads. Remove the pads and set them aside safely.

Step 2: Remove The Caliper Plate

After having disconnected and safely tucked the caliper away, you need to remove the caliper plate. This involves removing a couple of bolts located at the back of the caliper bracket. These bolts go through the caliper bracket and connect to the wheel hub. 

Sometimes these bolts are held in place with Loctite and may require a little extra effort to dislodge. 

Note: Before removing the brake disc, there may be a rotor screw or two on the rotor face. You must remove each rotor screw before attempting to dislodge the brake disc. If a screw has rusted in its screw hole, you may need an impact driver to dislodge it. 

Slot the head of the impact driver into the head of the screw and hit the other end of the impact driver. Try and turn the screw as you do so, and with a bit of luck, it’ll come loose. 

Step 3: Temporarily Reattach The Lug Nuts

It’s at this point where the brake rotor should just slide off the wheel. 
However, since that isn’t the case, we need to break the rust. 

Before doing that, it’s a good idea to reattach a lug nut or two temporarily. You just need to screw them on enough to stop the rotor from coming off and falling on someone’s foot while removing the rust. 

Doing so will also ensure no accidental damage to the threads, which can warp the wheel studs. 

Step 4: Remove The Rust

Now, you need to remove the rust. 

For this, you’ll probably start with a hammer. 

Almost any hammer will work, such as a:

Some note that using a metal hammer is more effective because it creates more vibrations, but this can damage the rotor if you’re hitting it directly. 

You can then start by hammering in between each lug nut. This is important because if you’re performing repairs and not a replacement, hitting the rotor itself can break it, separating it from the wheel hat. 

Often, giving it a few taps around the wheel hub is enough to pry the brake rotor off. 

Step 5: Grab Some Extra Equipment

If hammering hasn’t done the trick, you’ll need a backup plan. 
For this, you’ll need some extra parts: 

Step 6: Insert The Bolts Into The Threaded Holes At The Back Of The Rotor

If you’re lucky, there might be a threaded hole or two on the back of the brake disc. These threaded holes serve no other purpose than to help remove a stuck rotor. Slot a bolt with a washer through each threaded hole and secure them with the nuts. 

Then, with one wrench attached to the nut, use the other wrench to tighten the bolt. Then, make sure to switch between the two bolts, tightening them evenly

If you do this enough times, alternating between the rotor bolts and the brake disc should simply pop off. 

5 Tips To Help Free A Stuck Rotor

If the above steps haven’t helped free your rusted rotors, there are a couple of other methods available:

Tip #1: Rotate The Rotor

You can try loosening the bolts you installed in the bolt hole behind the rotor, putting the car in neutral, and releasing the parking brake. You can then rotate the disc rotor about 45° before tightening the bolts again. 

Applying the force to a different part of the rotor might also be what’s needed to break it free. You might need to rotate the rotor a few times to find out.

Tip #2: Use Penetrative Lubricant

Penetrative lubricant like PB Blaster or Liquid Wrench can be a major asset in your toolbox. By applying a generous amount on the wheel hub and the backside of the rotor, the lubricant can help dislodge any rust or corrosion. 

After giving the lubricant some time to take effect, you’ll probably need to hit the hat a few more times.

If you’re facing an adamant screw, feel free to use some penetrative lubricant on the screw hole.

Tip #3: Use A Puller

You’ll need a large enough rotor puller to grip around the back of your rusted rotors. There should be an indentation on the center of the rotor face. Using this indentation to secure the puller’s center bolt, you can then lock the jaws onto the backside of the rotor.

After applying some oil to the center bolt, you can then begin tightening the puller. If the rotor still doesn’t budge, hitting the puller’s center bolt with a hammer can help.

Tip #4: Apply Heat

If the stuck brake rotor still hasn’t dislodged, you may need to start applying heat with a propane torch. Applying heat to the areas in between the lug nut on the brake hat may be what’s needed to finally dislodge the stuck rotor.

Tip #5: Use A Breaker Bar

If you’re desperate to get your rusted rotors off, you might need to consider using a breaker bar and some leverage. 

If opting for his method, take some extra precautions. Using this much leverage can round out the bolt, and then you’re in a worse place than when you began. 

You’ll need a one-foot breaker bar and a cheater bar. Then, simply slot the end of the breaker on the bolt head and slot the cheater bar over the breaker bar. Make sure to slide the cheater bar all the way down, so you don’t bend the breaker bar. 

Then, gradually start applying pressure until the bolt begins to come loose. You should then be able to remove it using only the breaker bar. 

If you’ve tried all the above methods and still have no luck, you can always cut the rotor off with an angle grinder. Of course, this will work only if you’re installing a brand new rotor and not repairing old rotors. 

Now that we know how to remove a stuck rotor, let’s look at preventing it from happening again in the future.  

How To Prevent A Stuck Rotor In Future

No one wants to go through all that work again, especially if it’s avoidable. It’s often a time-consuming and exhausting job, requiring a good amount of effort and some specific tools. And even then, the most stubborn rotors may take a mix of all methods before finally dislodging. 

Next time you have your brake rotor repaired or replaced, make sure you do the following:

1. Clean The Rust And Corrosion

First, ensure you clean any rust and corrosion around the wheel studs. You can do this with a wire brush or even a wire brush drill attachment. Ensure you’re thorough in cleaning the sides and tops of the wheel hub since this is where it will rust the most.

2. Apply Some Grease

Then, you can ask the mechanic to put some lubricant like dielectric grease on the wheel hub and the backside of the wheel rotor. This is fantastic for preventing the two metals from corroding together in the future. 

Wrapping Up

With constant exposure to the elements, rust and corrosion can cause the brake rotor to weld to the wheel hub. If you’re in a pinch with a stuck brake rotor and unable to dislodge the two, your best bet is to arrange for a professional mechanic to examine the issue. 

Trying to separate the hub from the rotor face may require specialist tools. Some technical know-how can also go a long way as you’re going to encounter other essential components, such as the brake calipers. 

When in doubt, don’t stress. 
Reach out to a professional like RepairSmith and let them handle all the heavy lifting for you. They’ll send ASE-certified technicians to your driveway, ready to fix any rotor issues!