Galaxy    on 21 January 2007

Did the discs on my W-reg Mondeo last summer. I don't think they have changed the design on the later models. There certainly wasn't any sort of grubscrew retaining the disc, and, after removing the wheel and the caliper, the disc just went all floppy and loose without me doing anything to it. Having read all sorts of horror stories in the BR and elsewhere about brake discs that refuse to come off I was dreading doing this job, but I didn't have any real problems in the end.

Unfortunately it sounds like you haven't been quite so lucky.

I believe they tend to stick on the hub flange due to corrosion, and probably the best intitial thing to try is giving the flange a good soaking in WD40 as wayne1980 has suggested. Some say that Plus Gas is better than WD40. This to be followed by some gentle persuasion with a rubber or nylon mallet.

Other methods include applying heat to the hub, and cutting a radial slot into the disc and then using a cold chisel to open the slot, eventually driving it right down to the hub flange. However, both of these methods are potentially hazardous and can also destroy the wheel bearing in the process!

If the disc absolutely refuses to come off then you will, indeed, have to undo the hub nut and remove the disc and hub flange as one. You might be able to separate them on the workbench, or you will need to replace the flange as well. It will probably also need a new wheel bearing.

Robin Reliant    on 21 January 2007

I asked the same question here last week( N reg 1.8TDI), if you scroll back you will find the thread. The advice I got was give it some Plus Gas (I used WD40) and plenty of persuasion with a big hammer.

It worked.
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