Help with getting a rotor off

[Erskin]

Am attempting to inspect my friends brake side driveshaft 18 Tcat with 6k on it, he just purchased it. He has a terrible brake pulsation that will shake your hand when applying but otherwise goes smooth when off brake. I suspected the bearing and or driveshaft has worn like many have experienced on this site. Problem is the damn rotor will not come off the splines. When we removed the guards we noticed the c clip had chipped a corner off of it, maybe 1" of it was gone but it was still seated properly and appeared to be doing its job. We took the 3 tunnel bolts out and broke the caliper apart, removed pads. It will wobble and has some play but it acts like it's getting caught internally in middle of rotor on inner splines. They all look good, I even dremeled the outer edge splines a bit to see if it was catching there and it didn't make any difference. Any other suggestions as to why it won't come off? Rotor looks decent, not gouged or warped from what I can see just appears to be hung up on splines. thanks for any tips..

 

[earthling]

Can’t get brake rotor off drive shaft.

2017 Sidewinder, removed the snap ring on the drive shaft, split the caliper to remove the brake rotor, rotor will slide on shaft about a 1/16 of a inch in and out but it won’t pull off the shaft, I’ve move it in and out a 1000 times but it won’t come off, filed the splines on the end of the...

ty4stroke.com

 

[Motorhead]

I’ve seen 2 problems associated with brake rotors not sliding off as they should.

Rotor wears against the bearing and causes spline damage on that bearing side.
Shaft had to be cut to get all apart!

Other scenario that happened to me, someone accidentally got some loctite on the rotor shaft. I tried different pullers and a bit of heat to no avail, so I brought it back whereas the mistake was done under warranty services! They also used heat, pullers and pounded on it for 1/2 hour. Bearing and rotor were replaced once off!

Here’s a pic of worn rotor, bearing side!
This one came off easily but if worn just a bit more, it’ll curl that worn edge onto the shaft for Big trouble!

Not saying for sure that is your problem, but those 2 incidents I have seen, otherwise they come off pretty easy!

 

[sxr70001]

One thing you can try is to hit the end of the driveshaft with a plastic or rubber hammer while putting something behind the rotor to hold it out. It doesn't seem like much but sometimes you just need to get it past a certain spot.

 

[yamamarc]

Make a Plate with matching 3 hole as the caliper. And use 3 bolts to pull the caliper off,

 

[sab2022]

Erskin further info - Good luck
https://ty4stroke.com/threads/can’t-get-brake-rotor-off-drive-shaft.161323/

 

[Turboflash]

Travis created and posted template for a puller as posted by Yamamarc.
Or, Cat has 0744-067 (https://www.countrycat.com/oem-arct...0744-067-puller-bearing-brake-caliper-assy-f4)

 

[Motorhead]

Yes I downloaded and used that simple caliper puller (Thank you BOP) It’s got to be made with some thick steel, or it’ll bend. be very careful with amount of torque used on those bolts. Remember, the caliper bolt holes are aluminum so it can strip out threads. Hoping it’s just stubborn, and not damaged because of wear.

 

[Turboflash]

Yes I downloaded and used that simple caliper puller (Thank you BOP) It’s got to be made with some thick steel, or it’ll bend. be very careful with amount of torque used on those bolts. Remember, the caliper bolt holes are aluminum so it can strip out threads. Hoping it’s just stubborn, and not damaged because of wear.

Yes, that's true.
Cat puller uses a bolt and pusher (pushes on driveshaft) design. Once the 3 bolts are into caliper (alum) you don't have to turn them anymore. You just turn the center pusher. That might reduce chances of stripping or damaging caliper threads. I made one from BOP drawing out of 1/4" steel. Works great.

 

[1nc 2000]

Steering wheel puller works also.

 

[Sevey]

Had something similar to this A few years ago. The rotar had put pressure on the splines where the circlip is located and flared the edges, - so when the circlip was removed it would not slide off. I had to slide it back and forth for like 30 minutes slowly flattening the flaring. Use a triangular file and try and file some material off If you have the space. I eventuall got it off and had to file each spline back into shape. Has never happened since.

MS

 

[Erskin]

Thanks for all the suggestions guys.. he picked up a cheap $20 harbor freight 3 legged puller and it came of with only a few turns. Was hung up on the splines. Unfortunately, the shaft is quite worn and the bearing looks great as most people are finding. Aside from having to install a whole new shaft, has anybody had any success with the BOP taking up most of the severe slack and green loctite doing the rest? I would call this jackshaft pretty worn IMO but I just wasn't sure if guys had any success "half assing them" with BOP and loctite.

 

[stgdz]

You can send the shaft off to be rewelded and have a pin put on it. They will send you a new bearing to install

 

[stgdz]

Pin'd driveshaft with bearing fix

Saw this mentioned sometime last year and I had it bookmark'd but now I can't find it. Basically they pinned the driveshaft and then cut a small slot in the bearing. I believe they also welded and lathed the shaft of any worn down spots. It was a dealer out on the east coast that offered the...

ty4stroke.com

 

[Upstater57]

The good news is the season is over so you have time to figure things out. I would replace the shaft/rotor/bearing if I could get the parts. If you cannot get them, a welded shaft and pin the bearing would be my next choice.