Front rotors are stuck on hub?

the brake rotor is stuck onto the hub? Strike around the outer rim of the rotor sharply with a hammer, and not a small hammer....I am talking like a 3lb, mini sledge. strike and turn rotor, strike and turn. This will break the rust loose and allow the rotor to separate from the hub. Your rotor will either need to be turned to true it back up, or replaced after this, but it will remove it from the vehicle. if you apply some black molly grease or anti-seize to the hub when re-installing the new rotor this will prevent this the next time the brakes need serviced. Also remember to clean and grease the pins or caliper slides when servicing the brakes, this will prevent uneven pad wear.

Sit on your but and kick the tire with both feet. The tire is stuck. Some tire repairmen use a large sludge hammer and hit the tire,don't hit the rim.

Section 05-03C: Wheel Hubs and Bearings, Front Wheels, 4-Wheel Drive 1997 F-250/350/Super Duty Workshop Manual REMOVAL AND INSTALLATION Procedure revision date: 05/17/2000 Locking Hubs, Manual




Item Part Number Description 1 3A329 Halfshaft 2 3C132 Rolling Diaphragm Seal (Axle) 3 3299 Integral Spacer Needle Bearing Seal 4 3123 Bearing, Caged Needle 5 3105 Front Wheel Spindle 6 1190 Wheel Hub Grease Seal 7 4221 Inner Wheel Bearing (with Bearing Cup 4222) 8 1102 Front Disc Brake Hub and Rotor 9 4221 Outer Wheel Bearing (with Bearing Cup 4222) 10 - Pin (Part of 1195) 11 1195 Inner Lock Nut 12 1198 Lockwasher 13 1197 Outer Lock Nut 14 - Steel Thrust Washer
(Part of 3B458) 15 - Plastic Thrust Washer
(Part of 3B458) 16 - Splined Thrust Washer
(Part of 3B458) 17 3B457 Snap Ring 18 1K105 Hub Body 19 - Lock Ring (Part of 1K106) 20 1K104 Cap 21 1K104 Capscrew A - While Rotating Front Disc Brake Hub and Rotor, Tighten Inner Lock Nut to 68 Nm (50 Lb-Ft) to Seat Bearings. Back Nut Off 90 Degrees (1/4 Turn). B - Tighten to 217-278 Nm (160-205 Lb-Ft) C - Tighten to 4-6 Nm
(35-53 Lb-In) Removal

1. Separate cap assembly from hub body by removing the three Torx® head capscrews.
   
   
   
   
   
   
   
   
   

1. Remove the lock ring seated in the groove of the front disc brake hub and rotor (1102).
   
   
   
   
   

1. Remove the hub body assembly from the front disc brake hub and rotor. If the body is difficult to remove, install two capscrews and pull the body assembly out of the front disc brake hub and rotor.
   
   
   
   
   

Installation

1. NOTE: Do not pack the hublock body assembly or cap with grease. Excessive grease can cause excessive dialing effort and hub failure.
   
   Follow removal procedure in reverse order.
   

1. Tighten three Torx® head capscrews to 4-6 Nm (35-53 lb-in).
   

It could be a lemon replacement hub or it could actually be the tire. Check the tires tread for irregular wear patterns. If the hub was loose prior to change this could easily cause the tire to wear in a "choppy" fashion which can also cause a rough humming sound that I have often heard customers refer to as a grinding sound.

To change the rotors you will need to first remove the wheels, then remove the brake caliper and brake pads. Next, you will need to remove the caliper mounting bracket. Once you have done this, the rotors should just pull off. If they still seem stuck you can try tapping on them with a wrench as they may be stuck on the hub do the brake heat and pressure over time.

Raise vehicle and remove wheels. Disconnect brakeli
ne from caliper (if necessary). Remove caliper.

On models with free wheeling hub, set control handl
e to FREE position. On all models, remove hub
cover, bolt/washer and hub body. Use tapered punch
to open slits of conical washers. Remove axle shaft

snap ring (if equipped).

Straighten tabs of outer lock washer. Using Spindle
Socket (09607-60020), remove lock nut, lock washer

and adjusting nut. Remove thrust washer and outer b
earing. Remove axle hub and rotor. Remove grease se
al
and inner bearing. Press hub bolts out of axle hub.
Remove retaining bolts, and separate rotor from hu
b.

here is procedure

Section 04-01: Suspension and Wheel Hubs, Front 1996 Taurus, Sable Workshop Manual
REMOVAL AND INSTALLATION Wheel Hub Bolt Removal

1. Raise vehicle on hoist.
   

1. Remove wheel and tire assembly. Refer to Section 04-04 .
   

1. Remove disc brake caliper (2B120), and front disc brake rotor (1125). Refer to Section 06-03 .
   

Brake Shoe and Lining Removal

1. 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.
   

1. Raise vehicle on hoist. Refer to Section 00-02 .
   

1. 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).
   

1. Remove rear brake pin retainers (2N386). ( I think it is a T 40 torx bit you need)
   

1. 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.
   

1. Position disc brake caliper out of the way and support with wire to avoid damaging the disc brake caliper and front brake hose (2078).
   

1. Remove outer brake shoe and lining (2001) assembly from front disc brake caliper anchor plate.
   

1. Remove inner brake shoe and lining assembly.
   

1. Position lug bolt (1107) to clear front wheel knuckle (3K185).
   

1. Remove lug bolt from wheel hub (1104).
   
   
   
   

Installation

1. Install lug bolt into wheel hub.
   

1. Using a lug nut (1012), seat wheel hub bolt into wheel hub.
   

1. Install front disc brake rotor and disc brake caliper. Refer to Section 06-03 .
   

1. Install wheel and tire assembly. Tighten lug nut to 115-142Nm (85-104 lb-ft).
   

u will need to remove the brake cailper and the the brake rotor, then the hub retaining nut, that is a large metric nut, the bearing and hub must come off, then u will need to take this hub to a machine shop or the dealer and have the new bearing pressed in.
BCA/NATIONAL Part # 510078 {Ball Bearing Bore=1.5354" Outer Diameter=2.9134" Width=1.4173"}
Front Wheel PRICE: $47.99, PART SOURCE: Rockauto.com

you should only have to take off the tire and the calipers, and the caliper bracket, there is no hub on the front wheels. there should be 2 bolts holding on the caliper bracket, usually with a big allen screw. they may be stuck so use a hammer to tap them loose. good luck

Raise the vehicle up and remove the rims & tires

Remove the brake pads, and then remove the calipers from the caliper retention brackets, do NOT remove the brake hoses from the calipers.

Remove the caliper retaining brackets from the hub assemblies (2 large bolts on backside of the bracket)

Tap the brake rotors off of the hubs, hit them from the back side of the rotor.

No big mysteries here, this is a very easy job.