2002 Sienna brake rotors stuck

[xrogers]

Hello all,

I have a 2002 Toyota Sienna, and I'm trying to replace the brake rotors (like I have on numerous past cars). I found one reference to stuck rotors in a previous thread, with a single response---just pound the rotors, and they'll come loose.

I've been pounding for over an hour on one rotor, and nearly as long on the other, and have made no headway. I've used a long handle two-pound ball peen, and a short handle five pound mini-sledge.

Am I doing something wrong? Do I need a bigger hammer (or a longer handle on the sledge)? Has anyone had this problem and succeeded? What's the key? Would some sort of puller help? Is it time to give up and bring the car (with it's well-dented rotors) elsewhere?

Thanks much,

Clyde

[lelandstanford]

Does the rotor have two screws securing to the hub?

[xrogers]

No, unfortunately, no screws or threaded holes to use.

--clyde

[lelandstanford]

Try spray some WD40 between rotor/hub.

[xrogers]

I've soaked it with penetrating oil (PB Blaster) to no avail. Any other thoughts?

Thanks,

Clyde

[ttoyota]

I just did a 2004 Lexus this morning, front rotors. I played with hammers for an hour, then crowbars until I found a big enough one to budge them. I just read somewhere else to tighten screws into the empty screw holes and they should separate. Wish I would have known that about 6 hours ago.
I think most Toyota/Lexus brakes are the same.

[xrogers]

I wish my rotors had the screw holes to help remove them. I did finally get them off, but something pretty radical was required.

First, just to provide a little more background, my Sienna is a 2002, and has about 90,000 miles. It has been through 5 Minnesota winters, which have contributed to a pretty good rust buildup, wedging the rotors onto the hubs quite nicely. This is the first brake job the car has had.

I tried tapping with a rubber mallet, pounding with a 2# ball peen, and wailing with a 5# small sledge. I tried wd40 and pb blaster, and more pounding. I tried chipping away behind the rotors to remove rust and more pounding. After something like three hours work, nothing.

So I found two different web references from pro mechanics who claimed that when rotors were really stuck, they'd sawzall them off...

So you put a new blade in the sawzall, and cut through the rotor from the edge to the edge of the hat, and very carefully though the side of the hat just barely to the hub. Repeat on the other side of the rotor, 180 degrees from the first cut (be very careful not to cut into the hub). Tap with hammer, and off pops the formerly very stuck rotor. Put a new blade in the sawzall, and repeat on the other side.

I was really hesitant to do this, but if I ever have such a painful problem with rotors again, I'll do it again in a heartbeat. It took less than 10 minutes per side, and was surprisingly easy. And worked like a charm.

Thanks for the advice,

Clyde