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Thanks to Mike Crowell for contributing to this FAQ!
When trying to remove old front brake rotors, you may find that rust has seized the rotors to the wheel hubs, often to the point where banging at them with a BFH (Big Freaking Hammer) does nothing. I stumbled across a solution so simple and ingenious, I can't help but think Saab designers built the brake assembly this way on purpose.
To remove the rotors:
1) Remove (and hang) the front wheel calipers as you normally would. 2) Using the bolts that attach the caliper to the hub, tighten the bolts in the mounts until they make contact with the old rotor. You will notice that these bolts not only are threaded their entire length, they are long enough to make contact with room to spare. 3) Continue to alternately tighten each bolt against the old rotor. The bolts will push the rotor off the hub on that half of the rotor. Once the rust bond is broken, a tap with a hammer on the other half of the rotor will free the old rotor completely.
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