Brake job from HELL!!!!!!

Contour Enthusiasts Group Archives

So this girl at work tells me that her car is making funny noises. I drive it and the pads are metal on metal. I tell her this and order new rotors and pads. I've changed brakes on numerous cars and it's quite easy and takes me about an hour to do the fronts on every other car I have done. I rip everything off and the rotor will not come off. This is an '01 Cougar. It has 50,000 miles with original brakes. The rotors is rusted/melted/welded(?) onto the hub. I soak it in PB Blaster for 2 days everywhere. I try with a hammer, a sledge, crowbar, blow torch, you name it....all I get off are chunks of the rotor with the sledge. I decide to undo the spindle nut. I pound on the rotor some more and the entire hub comes off as expected. I look closer at it and it is totally rusted on there. It's not coming off.

I am debating if I should get new hubs or try to have a shop press them off the crappy rotors? I need to get the bearings pressed as well now plus they are totally dry.

My question is....do you think I should get new hubs or try to get the old ones out?
I need to get the bearings repacked and pressed....what do I need to replace? Seals? Bearings? What? Can I use the old bearings? I need a list.

I just sold my SVT Contour and I gave the guy my Haines so I am SOL...any help is appreciated. I'll take some pics tomorrow!!!!

If the bearing were 'dry' when you took them off, then you should replace the whole works. Bearings and seals should run you LESS then 20 bucks. I don't know about how much the hubs cost. For that all to be stuck on there that bad, something got REALLY hot.

I have done virginal brake jobs on cars with 75k, 100k, and 125(!!!!)k. Sometimes they are a little bit rough, but NEVER that bad. Replace the works, if for nothing else but safety.

BTW, you SHOULD do both sides.

I agree...don't skimp when it comes to brakes.

And when you install the new hubs and rotors, apply anti-sieze to the surface where they mate as well as to the surface where the rotor mates to the wheels. Next time the rotors will come off much easier.

My dad once replaced the pads and shoes on my 81 Cougar. He didn't route the wires in the rear drums correctly and the non-functioning rear brakes caused the crappy front pads to wear out in a manner of weeks. So I redid the front rotors and fixed what Dad screwed up on the rears and never let my dad work on a critical car component again.

congratulations

Originally posted by patman:
congratulations

I am really not in the mood right now. [censored] off.

LMAO!

Originally posted by Beowulf:

Originally posted by patman:
congratulations

I am really not in the mood right now. [censored] off.

calm down homie!

i used some antiseize behind my wheels and up againt the rotor hub and will never again. as the wheel spins the antiseize is spun to the edge and kicked out onto the wheel. didnt look good.

Either use a better anti-sieze or use it more gently. I've never had it get on the wheels.

Originally posted by Daddy Phat Sacks:

Originally posted by Beowulf:

Originally posted by patman:
congratulations

I am really not in the mood right now. [censored] off.

calm down homie!

I was tired and annoyed with uncooperative equipment. Sometimes working from home is a bad thing.

I know what you're talking about. Took me and a friend 9hrs to do brakes last time on my car. The front rotors were seized to the hubs. Not pretty.

My rotors were stuck pretty good after only a year of being on the car, we used an impact hammer/chisel and it came off rather quickly. But that sounds like a PITA. Round here it was like $150 or $200 for new hubs, bearings and pressing at a dealer.

when doing brakes, only 7 tools are needed. (including the tool who will be working on the car

)

1. tool who will be working on the car
2. tire iron
3. jack of suitable capacity.
4. BH (big hammer)
5. BFH (big F***ing Hammer)
6. BMFH (Big MotherF***ing Hammer)
7. RGDBMFH (really GodDamned Big MotherF***ing Hammer)

I took the hubs to a press guy today. It took 21 tons of force to get the rotors off the hubs.

ho.........leeeeee.........sh!t!!!!!!!!!

Originally posted by Stryker:
when doing brakes, only 7 tools are needed. (including the tool who will be working on the car )

1. tool who will be working on the car
2. tire iron
3. jack of suitable capacity.
4. BH (big hammer)
5. BFH (big F***ing Hammer)
6. BMFH (Big MotherF***ing Hammer)
7. RGDBMFH (really GodDamned Big MotherF***ing Hammer)

You forgot the C-clamp.

Originally posted by KTPdave:
I took the hubs to a press guy today. It took 21 tons of force to get the rotors off the hubs.

Thats it??? We have 1000 ton presses at work. [censored] the hydraulic torque wrench goes well over 6000ft lbs....Nothing like torquing 30-40mm bolts to there yeild and having them break

That's it? YEA THAT IS IT! 20 tons is a lot for some rust on a tiny rotor!

i can see needeng 21 tons of pressure to get a rotor off of a peterbuilt (though they dont have them) but a coog? , thats insane! it must have gotten so hot the hub welded itself to the rotor...ewwwy.