I am trying to replace the front rotors on my 2003 Expedition. Once you get the calipers off, it looks like they should pop off. I have tried a rubber mallet.

Is there a secret? Heat up the rotor? Get a big gear puller? Take it to a dealer?

Thanks

Get a bar in behind the caliper and the steering knuckle and apply outward pressure. Then have someone with a big chisel and a small sledge whack the rotor right where it hits the hub at about the same place on the axis that you are prying on. Don't pull too hard on the prybar- you can bend the rotor's center piece. In bad cases, heat helps but not too much. Liberal anti-seize on reinstallation as well as on the inside of the alloy wheel's pilot hole

Thanks Chris,

Once I knew it had to come off, I used a bigger hammer. 3 hours for the one side, less than an hour for the second. The 4 pads were worn evenly down to 1/16 left in 50k, Lets see how the Power Slot and Satisfied SUV pads last.

F

Some rotors in 2 places where it is around the hub have small threaded holes. Use a couple of bolts and alternate turning them and it should come off. Some rotors dont have this which makes it a pain.

Finman

The Powerslots work very well- much better than the cross-drilled ones. I have been using the new EBC pads- the green ones. The Excursion stopped very well stock but the rotors were constantly warping. The powerslots/ebc's improved the braking and pedal feel and got rid of the pad dust. No warpage/pulsation either.

Do you mean the rotors were "Rusted" on? On a Ford?!!!

Spray around the studs and hub with penetrating oil and give it a couple of shots.......usually does it.....but then again it is a FORD!!

Just did the front and rear on mine tonight, a 5# sledge loosened them right up and they slid right off.