Mansfield
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| posted on 23/8/08 at 03:25 PM |
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Tin tip trouble - removing Mondeo brake discs
I didn't think anything could be easier than changing front discs and pads on a MkII Mondeo, that is until I tried it.
The disc is rusted to the hub it seems, any tips for getting it off?
I have hit it as hard as I can, with a heavy copper mallet, all around the disc and it has not budged at all. I am not sure I really want to drive it
with the dents in the disc but unless I get it off, I might have to.
Any tips?
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DRC INDY 7
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| posted on 23/8/08 at 03:32 PM |
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Hit it from behind with a steel hamer and keep moveing the disc it will come of
https://www.facebook.com/groups/462610273778799/
Puddle Dodgers Club
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ReMan
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| posted on 23/8/08 at 03:47 PM |
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As long as there are no clippy washer things on the studs and no screws between the studs holding the disc on, then you are not hitting it hard
enough
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grub
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| posted on 23/8/08 at 03:57 PM |
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ive been there you will most likely end up with no disc left to hit go on give it another
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Peteff
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| posted on 23/8/08 at 04:03 PM |
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Hit the middle of the bell with a steel hammer and it will smash eventually if it doesn't come loose then it will come off easily.
yours, Pete
I went into the RSPCA office the other day. It was so small you could hardly swing a cat in there.
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Mansfield
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| posted on 23/8/08 at 04:05 PM |
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Nice to hear someone else has been there, were you as suprised as I was when it didn't come off?
I have been back out and really hit it, front and back, again and again, not a sausage.
I have put it back together in disgust.
Do you think getting it hot with a bit of a drive would help? Not that I really want to drive at all right now. of course.
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Mansfield
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| posted on 23/8/08 at 04:08 PM |
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quote:
Originally posted by Peteff
Hit the middle of the bell with a steel hammer and it will smash eventually if it doesn't come loose then it will come off easily.
EEEK! I am not used to such brutallity, but I am willing to try, am I hurting the bearings by doing that?
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Mansfield
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| posted on 23/8/08 at 04:14 PM |
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I have just read this after a bit of googling.
if you are replacing the discs cut them off using an angle grinder
use a radial cut with a 9 in grinder held horizontally in line with the centre of
the disc and cut through the disc from the front
continue cutting until you reach the boss and cut 2 or 3mm into the boss
finally use a hacksaw in the slot you have cut until you have cut through
to the wheel carrier (you will see daylight at the back of the cut)
gently tap off the disc
It's only a bloody Mondeo, this is all a bit 'farmyard' for me.
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adithorp
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| posted on 23/8/08 at 04:20 PM |
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Mondeo disc are well known for this. Hitting it wont help; they duild up rust behind the hud flange more than other cars and trying to knock it of
just wedges it on harder.
Take a cutting disc in the angry grinder. Carefully cut accross the disc centre at a tangent to the centre, go across and behind one stud. Dont go
through to the flange. Then cut around the edge of the "top hat" radially just far enough down to be behind the flange from one end of
the first cut to the other. Cut right through. Now go into this slot with a big chissle and the section will break off and the disc will come free.
Sound drastic but its proved to be the quickest way. Don't cut deep enough with the first cut to go into the flange.
adrian
"A witty saying proves nothing" Voltaire
http://jpsc.org.uk/forum/
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theconrodkid
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| posted on 23/8/08 at 04:26 PM |
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i wouldnt go driving it after you have beaten the crap out of the poor thing,squirt some wd40 through the wheel stud holes and have a cuppa,get a
bigger hammer and continue as you were
smack it where the wheel mounts,that should break the rust
[Edited on 23/8/08 by theconrodkid]
who cares who wins
pass the pork pies
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chasmon
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| posted on 23/8/08 at 04:26 PM |
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Been there done that...
I chain drilled holes through the disc and then using the depth stop to avoid damage to the hub itself. Holes don't have to meet as once
they're all drilled on one side you simly use a chisel (masonry) and a lump hammer and drive it into the slot. All the holes break through and
the disc comes off.
1st one took me 4 hours of head scratching 2nd one took less than 30 minutes.
On reassembly copper grease is your friend!!!!
C
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Peteff
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| posted on 23/8/08 at 04:28 PM |
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I just thrashed it with a 2lb hammer and the bell (top hat) broke, no bearing problems and the car was used for ages after. The angry grinder sounds a
gentler way of achieving the same result.
yours, Pete
I went into the RSPCA office the other day. It was so small you could hardly swing a cat in there.
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Mansfield
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| posted on 23/8/08 at 04:28 PM |
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It does sound drastic, but I can see why it needs to be. I stopped hitting it when I saw the what was holding it on. The rust between the outside
diameter of the hub and the inside diameter of the bell, is what it looks like to me.
I cant quite follow your cutting instructons, bear with me I will do a sketch.
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Mansfield
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| posted on 23/8/08 at 04:33 PM |
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I cant keep up with all your replies, but they are all appreciated. I think I am grinding it Pete - it does sound gentler and I only have a 1lb
hammer.
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mcerd1
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| posted on 23/8/08 at 04:37 PM |
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one of the granada's I took apart had sat in a field for 5 years - I had to put the hubs in a 30 ton press to get the discs off
the discs had rusted up behind the hub so there was no way they'd have come off with a hammer
[Edited on 23/8/08 by mcerd1]
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Mansfield
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| posted on 23/8/08 at 04:41 PM |
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First cut in red as I read your reply.
 
Description
Or did you mean here?
 
Description
[Edited on 23/8/08 by Mansfield]
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rusty nuts
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| posted on 23/8/08 at 04:58 PM |
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Get your self a "proper" hammer . I have a 4lb long handles club hammer that I only tend to use on Mondeo discs. Have found it a waste of
time trying to knock them off from behind , I tend to hit towards the center of the car at the middle of the braking surface . Keep hitting in one
point until the disc breaks then keep on until the braking surface is all off . After that a few clouts will remove the part that fits over the drive
flange until a small chisel can be inserted between the remaning parts. Has taken me longer to type this than it takes to remove using this method.
Take care and use goggles etc. and DO NOT do this without properly supporting the car.
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adithorp
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| posted on 23/8/08 at 05:01 PM |
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As in picture 2. Then around the edge below the flange so as not to go into it. Then knock out the segment. I've done dozens this way and now
takes less than 10mins each.
First cut only goes across the centre, not the brake surface but not deep enough to go through to the hub flange.
adfrian
[Edited on 23/8/08 by adithorp]
"A witty saying proves nothing" Voltaire
http://jpsc.org.uk/forum/
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Mansfield
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| posted on 23/8/08 at 05:23 PM |
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Thanks for all the help.
I will post up some pictures tommorrow that hopefully wont include ones with mangled fingers.
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redscamp
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| posted on 23/8/08 at 05:36 PM |
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i have had sucess using a reciprocating saw and a two legged puller.
i prefer steel saw dust to angle grinder dust and sparks.
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johnston
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| posted on 23/8/08 at 06:20 PM |
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How do you live without a 4lb long shaft block hammer?
Don't you know the saying "if at first you don't succeed use a bigger hammer"
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Michael
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| posted on 23/8/08 at 07:09 PM |
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Put the Kettle on!
Boiling water over disc and a large wack with hammer, should shift it.
Same thing happens with the late Escorts, i just kept hitting and rotating from behind.
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Mansfield
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| posted on 24/8/08 at 08:43 PM |
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Well I ended up using a combination of all of the suggested methods.
As it is some sort of cast iron material, it is easy to drill, brittle when hit and nice to grind.
I had every intention of grinding it off, but couldn't quite get the access I wanted. I am not a big fan of grinding in confined spaces, I
always seem to lose some skin.
I started out chain drilling and beating a segment out, hacksaw down to the hub carrier and then grinding across. Several clubs with the big hammer
and the 'bit' fell out. The rest of the disc yeilded but only after some heavy beating.
Thank you so much for all of your help, I had no idea it would be so awkward, but it is not too bad a job if you are prepared for it.
I only got one side done today due to domestic responsibilities, tommorrow I wont bother with the drill as it is easy enough to saw and I have already
bust 2 of my favourite drill bits.
 
Description
[Edited on 24/8/08 by Mansfield]
[Edited on 24/8/08 by Mansfield]
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rusty nuts
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| posted on 24/8/08 at 08:57 PM |
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Don't bother sawing or drilling just hit it with THE BIG HAMMER
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Mansfield
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| posted on 24/8/08 at 09:17 PM |
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My biggest hammer is 1/4 the size of yours and I dont like using that much. I have too much mechanical sympathy to use your method, but I can see how
it works after doing one side. The disc just breaks if you give it enough.
Interestingly, I needed to drive the car to go and get a cold chisel to help today and all the brake judder had gone. All the bad bits on the outside
of the disc had been beaten off/peined over and the car was much nicer to drive.
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