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Thread: Brake Rotor Removal - Suburban 2500 4WD

  1. #1
    Registered User Big T's Avatar
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    Default Brake Rotor Removal - Suburban 2500 4WD

    Looks like I'm paying the price for buying a Suburban from Illinois. In the middle of doing pads and rotors, but cannot get the 4 bolts off holding the hubs. Already broke a Craftsman socket. Bought impact sockets. Did break one bolt free, but it continued to be beligerent and now the bolt head is rounding off.

    So what do I do? I've applied PB Blaster. Do I apply heat? Do I risk ruining my CV boots with the heat? How do I get the bolts that are rounded out?
    1999 Chevy Suburban K2500 4x4 w/ 6.5TD 190K miles. 4L80E and 3.73 rear gears. HD lift pump, ATT, Heath HO injectors, 4" Diamond Eye Turbo Back exhaust, Warpspeed x-over, deleted soot trap , D-Tech pmd behind bumper, Heath programming for ATT, Pillar mounted gauges: EGT, Boost, Tranny Temp. Replaced IP at 130K. HID light conversion with All-4-On-Hi. Forged Alcoa wheels.

    My son's 1994 GMC Suburban K2500 4x4 w/ 6.5TD 243K miles. 4L80E and 4.10 rear gears. Buddy 4 position tune. Rebuilt Bosch injectors and new Duraterm glows. HO water pump with Dmax fan, HD fan clutch and new AC Delco 195 T-stats. Diamond Eye 3" Downpipe and 4" exhaust, deleted soot trap. Warp speed 2.5" mandrel bent crossover. D-Tech PMD mounted behind the bumper. Pillar mounted gauges: EGT, Boost, Tranny Temp. Rancho 9000 shocks. Rebuilt front end and steering box tightened. Forged Alcoa wheels.

  2. #2
    Registered User ak diesel driver's Avatar
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    I ended up cutting the head off one of mine. They are a specialty bolt so you'll have to junkyard one.
    96 gmc k2500 4" exhaust, marine inj, #9 resistor, GL4, turbomaster, duraterms,-1.94 TDCO,FTB, remote pmd, isspro pillar gauges, lift pump relay added ,141 block, 2 1000 w block heaters, 2 150w glue on oilpan heaters, 2 150w glue on transpan heaters, 97 K47 air filter , IP replaced at 229k ,gear drive set awaiting install, Parts for intercooler waiting to be installed

    94 k1500 excab sb 6.5 plow truck. Fisher plow w/engine driven pump, F intake, h/m turbomaster, plowing chip by Buddy, remote PMD w#9 resistor, Duraterms

    96 k3500 CC 6.5 dually
    94 k2500 excab lb 6.5 parts truck
    00 burb 5.3 wifes
    70 Ford reg cab lb 428 cj richmond 5spd lockers 35s
    75 Vette built 383 needs work
    62 Tempest convertible way on the back burner project
    85 Honda VF1000R
    90 P30 Cummins BT4 work van
    90 Int SA dump w/trailer
    416c backhoe

  3. #3
    Registered User Big T's Avatar
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    What did you use to cut the head off?

    I've got half of them out, the others are not coming. Coincidentally, the front ones on both sides.
    1999 Chevy Suburban K2500 4x4 w/ 6.5TD 190K miles. 4L80E and 3.73 rear gears. HD lift pump, ATT, Heath HO injectors, 4" Diamond Eye Turbo Back exhaust, Warpspeed x-over, deleted soot trap , D-Tech pmd behind bumper, Heath programming for ATT, Pillar mounted gauges: EGT, Boost, Tranny Temp. Replaced IP at 130K. HID light conversion with All-4-On-Hi. Forged Alcoa wheels.

    My son's 1994 GMC Suburban K2500 4x4 w/ 6.5TD 243K miles. 4L80E and 4.10 rear gears. Buddy 4 position tune. Rebuilt Bosch injectors and new Duraterm glows. HO water pump with Dmax fan, HD fan clutch and new AC Delco 195 T-stats. Diamond Eye 3" Downpipe and 4" exhaust, deleted soot trap. Warp speed 2.5" mandrel bent crossover. D-Tech PMD mounted behind the bumper. Pillar mounted gauges: EGT, Boost, Tranny Temp. Rancho 9000 shocks. Rebuilt front end and steering box tightened. Forged Alcoa wheels.

  4. #4
    Registered User ak diesel driver's Avatar
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    grinder
    96 gmc k2500 4" exhaust, marine inj, #9 resistor, GL4, turbomaster, duraterms,-1.94 TDCO,FTB, remote pmd, isspro pillar gauges, lift pump relay added ,141 block, 2 1000 w block heaters, 2 150w glue on oilpan heaters, 2 150w glue on transpan heaters, 97 K47 air filter , IP replaced at 229k ,gear drive set awaiting install, Parts for intercooler waiting to be installed

    94 k1500 excab sb 6.5 plow truck. Fisher plow w/engine driven pump, F intake, h/m turbomaster, plowing chip by Buddy, remote PMD w#9 resistor, Duraterms

    96 k3500 CC 6.5 dually
    94 k2500 excab lb 6.5 parts truck
    00 burb 5.3 wifes
    70 Ford reg cab lb 428 cj richmond 5spd lockers 35s
    75 Vette built 383 needs work
    62 Tempest convertible way on the back burner project
    85 Honda VF1000R
    90 P30 Cummins BT4 work van
    90 Int SA dump w/trailer
    416c backhoe

  5. #5
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    Default

    If you can use heat try Sea Foam/Deep Creep they are the exact same product. Deep Creep is the aerosol version.
    I've had my best luck with that product for things that required heat.

    You're from California and you bought a Suburban from Illinois?
    What are ya? Crazy?
    Even I try to avoid buying used vehicles from the rust belt.

    Below is where I got my front bearing assemblies if you find yourself in need. Seems to be a good Made in the USA product for a good price.

    Please see http://mibearings.com/HUB_ASSEMBLY_DIAGRAMS.html for diagrams that will help expain the specifications.
    I have also attached images of the hubs below
    Please let me know if these will work for you.
    Don't hesitate to contact me with any questions or comments.
    Thanks,
    Luke Rehmann
    MIBearings LLC
    US Toll Free: 877-929-7280
    Int. +1 231-929-7280
    http://MIBearings.com
    http://www.CVAxles.net
    http://www.CorvetteWheelBearings.com
    Full line of Engine and Undercar Parts.
    98 GMC Suburban 2500 6.5 4x4 235,000 mi, FS2500, new timing chain, gears, Fluidamper & remote PMD, braided stainless oil cooler lines

    96 GMC 6.5 Suburban 1500 4x4 240,000 mi; Amsoil bypass & remote transmsision filters
    new timing chain, gears, fluidamper & remote PMD, braided stainless oil cooler lines

    95 Tahoe 2 door 4x4 6.5 240,000 mi;
    Stainless mandrel 3" exhaust, Amsoil Bypass filter, new timing chain, gears, Fluidamper, transmission, 3.73 rear end & remote PMD, braided stainless oil cooler lines

    1989 GMC Sierra 2500 2wd 5 spd get-rag trans had 108,000 mi. in 92 when the odometer broke. 7-800,000 miles on the truck. Installed a GM crate 6.5 non-turbo & FS 2500 in 2000 about 400,000 miles on the motor
    new timing chain, gears, Fluidamper & IP
    locked up and sold.

    95 Chevy C2500 xtra-cab 2wd 6.5 240,000 miles, remote PMD

    91 international 4700 low pro, spicer 6 speed, DTA 360 with 18' van box 500,000 miles plus.

    NRA Life Member for over 30 years
    Vote Freedom First

    1994 chev K3500 crew cab SRW 5 speed 4x4 230,000 miles
    PMD with heat sink. FS2500 bypass filter, The engine oil cooler lines are not leaking, Knock wood

  6. #6
    Registered User Big T's Avatar
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    "You're from California and you bought a Suburban from Illinois?
    What are ya? Crazy? Even I try to avoid buying used vehicles from the rust belt."

    By and large, the truck was quite clean and the price was right. Had all the mods folks on this site would want, including programming and ATT and the 4wd that I need. Only body rust was a couple dots on the lower edge of the driver's side barn door which can be easily addressed. The suspension stuff, especially the front, is rusty. That is what I'm paying the price on right now. Otherwise, love the truck and plan to have it many years. For the price I got it, there will be minimal depreciation in value, unlike my wife's Mercedes SLK convertible.

    Should I assume I'm going to need new bearing/hub assemblies? Truck has 160K miles on it. $350 worth of bearing/hubs, new rotors/pads, this getting to be pricey. If I paid someone to do this, it would easily be in the $1200 range by now.
    1999 Chevy Suburban K2500 4x4 w/ 6.5TD 190K miles. 4L80E and 3.73 rear gears. HD lift pump, ATT, Heath HO injectors, 4" Diamond Eye Turbo Back exhaust, Warpspeed x-over, deleted soot trap , D-Tech pmd behind bumper, Heath programming for ATT, Pillar mounted gauges: EGT, Boost, Tranny Temp. Replaced IP at 130K. HID light conversion with All-4-On-Hi. Forged Alcoa wheels.

    My son's 1994 GMC Suburban K2500 4x4 w/ 6.5TD 243K miles. 4L80E and 4.10 rear gears. Buddy 4 position tune. Rebuilt Bosch injectors and new Duraterm glows. HO water pump with Dmax fan, HD fan clutch and new AC Delco 195 T-stats. Diamond Eye 3" Downpipe and 4" exhaust, deleted soot trap. Warp speed 2.5" mandrel bent crossover. D-Tech PMD mounted behind the bumper. Pillar mounted gauges: EGT, Boost, Tranny Temp. Rancho 9000 shocks. Rebuilt front end and steering box tightened. Forged Alcoa wheels.

  7. #7
    Registered User Big T's Avatar
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    Alright, got 4 replacement bolts from the dealer.

    Tried heat and the bolt removers; not happening.

    The bolts are recessed, so a grinder will eat into the steering knuckle. Besides, my grinder is up at our place in Big Bear. So this is not currently an option.

    Trying to drill the bolt heads, but that is very slow going. Also, the drill chuck is rubbing thru the CV boot, so I'll be looking to replace those.

    QUESTION: Can I remove the entire steering knuckle by removing the upper and lower ball joints and sliding it off the axle? If so, then I could get a cleaner shot at drilling this.

    BTW the hub/bearing price at the dealer was $720 for just one side. Yikes! I like the link pricing above much better.
    1999 Chevy Suburban K2500 4x4 w/ 6.5TD 190K miles. 4L80E and 3.73 rear gears. HD lift pump, ATT, Heath HO injectors, 4" Diamond Eye Turbo Back exhaust, Warpspeed x-over, deleted soot trap , D-Tech pmd behind bumper, Heath programming for ATT, Pillar mounted gauges: EGT, Boost, Tranny Temp. Replaced IP at 130K. HID light conversion with All-4-On-Hi. Forged Alcoa wheels.

    My son's 1994 GMC Suburban K2500 4x4 w/ 6.5TD 243K miles. 4L80E and 4.10 rear gears. Buddy 4 position tune. Rebuilt Bosch injectors and new Duraterm glows. HO water pump with Dmax fan, HD fan clutch and new AC Delco 195 T-stats. Diamond Eye 3" Downpipe and 4" exhaust, deleted soot trap. Warp speed 2.5" mandrel bent crossover. D-Tech PMD mounted behind the bumper. Pillar mounted gauges: EGT, Boost, Tranny Temp. Rancho 9000 shocks. Rebuilt front end and steering box tightened. Forged Alcoa wheels.

  8. #8
    Registered User ak diesel driver's Avatar
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    You won't be able to disconnect the ball joints and get everything to come off because the axle shaft going thru the hub won't let it drop. If you sawsall the ball joints then it can slide straight out.
    96 gmc k2500 4" exhaust, marine inj, #9 resistor, GL4, turbomaster, duraterms,-1.94 TDCO,FTB, remote pmd, isspro pillar gauges, lift pump relay added ,141 block, 2 1000 w block heaters, 2 150w glue on oilpan heaters, 2 150w glue on transpan heaters, 97 K47 air filter , IP replaced at 229k ,gear drive set awaiting install, Parts for intercooler waiting to be installed

    94 k1500 excab sb 6.5 plow truck. Fisher plow w/engine driven pump, F intake, h/m turbomaster, plowing chip by Buddy, remote PMD w#9 resistor, Duraterms

    96 k3500 CC 6.5 dually
    94 k2500 excab lb 6.5 parts truck
    00 burb 5.3 wifes
    70 Ford reg cab lb 428 cj richmond 5spd lockers 35s
    75 Vette built 383 needs work
    62 Tempest convertible way on the back burner project
    85 Honda VF1000R
    90 P30 Cummins BT4 work van
    90 Int SA dump w/trailer
    416c backhoe

  9. #9
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    Careful use of a torch to melt candle was into the threads has proven time and again to beat any penetrating fluid for me.
    02 DMAX
    99 K2500 Sub, 3.73, optic bump, #9, stainless oil cooler lines, new glows, new injectors, 3" downpipe, 4" Diamond Eye exhaust with MBRP muffler, 285's, turned up T-bars, Timbrens, boost gauge, Walbro, high idle, Dmax fan, New Hayden fan clutch modded, Dual alternators. Still need FTB, pyro, & ATT.

  10. #10
    Well it hits on 7 of 8... WarWagon's Avatar
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    You can drop the axles out of the way. Unbolt the flange and then the spline should with a whack (or two dozen) should come out of the hub. CV boot replacements kits should be available without the entire axle shaft.
    Not enough room in sig for all the stuff I have that LeroyDiesel.com sells.

    2003 Dodge Ram 3500 SLT QC LB HO Cummins 6 speed handshaker w/ Pacbrake. Factory 3rd pedal anti theft.

    1993 Chevy "Patch" K2500 6.5 Diesel LB project beater... Now a 6.2 re-power w/6.5 NA heads. Gapless rings. Walbro FRB-5. A-Team Turbo. ARP head studs. 6 banger Trans tune chip I think I have changed, replaced, or tightened every bolt and nut on this thing!

  11. #11
    Northern Lights Sunshine's Avatar
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    Had the same problem, this guy I know said he could bring home from work this induction heater to get heat into the bolts we go 2 out of 8 the other 6 heads were round,I used Dremel with a flexible axel and Speedclic metal cutter.
    Paul...

    95..6.5TD "F" 4x4 Chevy Suburban K1500,4L80E,With A 3.42,posi...Heath`s PLG Empro,
    HO Injectors...Remote FSD..2.5" X-Over 3"-4" exhaust 5" to Tell a Tail..., Feed The Beast mod...Walking J`s Fittings Kit......
    3 DiPricol Gauges on "A" pillar...
    NewRocker Buttons @ 120mil/195Km...
    Fluidamper... Heath`s HD Cooling System Upgrade... Lube Specialists Oil Cooler kit....
    A-Team Turbo... no waste gate...
    Customized Upper Intake, 1" Custom "Throttle Body" spacer "Thanks to member Paveltolz"--
    GMTDScan Tech user "uff" #126

    1955 MK VII "M" Jaguar...190 hp. 6 seats, auto gear, came from California 2 Norway 1988 NO RUST...

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    Registered User Big T's Avatar
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    Quote Originally Posted by Sunshine View Post
    Had the same problem, this guy I know said he could bring home from work this induction heater to get heat into the bolts we go 2 out of 8 the other 6 heads were round,I used Dremel with a flexible axel and Speedclic metal cutter.
    I was thinking Dremel, but did not know whether they had a metal cutter that would do the job. I'm still going to replace hubs, axles and ball joints while doing this. I figure that the truck is at half life (162K miles) and all the parts in this area are showing the wear, so there's no sense in trying to half ass it such as rebooting an axle when new ones are just $70. So new axles, new hub bearing, new ball joints, new rotors, new pads, probably new calipers, new brake hoses. Am I missing anything?
    1999 Chevy Suburban K2500 4x4 w/ 6.5TD 190K miles. 4L80E and 3.73 rear gears. HD lift pump, ATT, Heath HO injectors, 4" Diamond Eye Turbo Back exhaust, Warpspeed x-over, deleted soot trap , D-Tech pmd behind bumper, Heath programming for ATT, Pillar mounted gauges: EGT, Boost, Tranny Temp. Replaced IP at 130K. HID light conversion with All-4-On-Hi. Forged Alcoa wheels.

    My son's 1994 GMC Suburban K2500 4x4 w/ 6.5TD 243K miles. 4L80E and 4.10 rear gears. Buddy 4 position tune. Rebuilt Bosch injectors and new Duraterm glows. HO water pump with Dmax fan, HD fan clutch and new AC Delco 195 T-stats. Diamond Eye 3" Downpipe and 4" exhaust, deleted soot trap. Warp speed 2.5" mandrel bent crossover. D-Tech PMD mounted behind the bumper. Pillar mounted gauges: EGT, Boost, Tranny Temp. Rancho 9000 shocks. Rebuilt front end and steering box tightened. Forged Alcoa wheels.

  13. #13
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    I have used stud remover sockets on rounded heads with good luck before.

    If you are replacing the bearing assembly and axel assembly I'd use the torch and heat things up a might. I'd stay away from the ball joints unless you are replacing them also. I've been having to replace my ball joints at about 230,000 miles but have many that are over that.

    Don't buy the new Cardone axles. They are made in China. The Cardone rebuilts are done in Philidelphia I believe.
    98 GMC Suburban 2500 6.5 4x4 235,000 mi, FS2500, new timing chain, gears, Fluidamper & remote PMD, braided stainless oil cooler lines

    96 GMC 6.5 Suburban 1500 4x4 240,000 mi; Amsoil bypass & remote transmsision filters
    new timing chain, gears, fluidamper & remote PMD, braided stainless oil cooler lines

    95 Tahoe 2 door 4x4 6.5 240,000 mi;
    Stainless mandrel 3" exhaust, Amsoil Bypass filter, new timing chain, gears, Fluidamper, transmission, 3.73 rear end & remote PMD, braided stainless oil cooler lines

    1989 GMC Sierra 2500 2wd 5 spd get-rag trans had 108,000 mi. in 92 when the odometer broke. 7-800,000 miles on the truck. Installed a GM crate 6.5 non-turbo & FS 2500 in 2000 about 400,000 miles on the motor
    new timing chain, gears, Fluidamper & IP
    locked up and sold.

    95 Chevy C2500 xtra-cab 2wd 6.5 240,000 miles, remote PMD

    91 international 4700 low pro, spicer 6 speed, DTA 360 with 18' van box 500,000 miles plus.

    NRA Life Member for over 30 years
    Vote Freedom First

    1994 chev K3500 crew cab SRW 5 speed 4x4 230,000 miles
    PMD with heat sink. FS2500 bypass filter, The engine oil cooler lines are not leaking, Knock wood

  14. #14
    Registered User Big T's Avatar
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    Quote Originally Posted by jrsavoie View Post
    I have used stud remover sockets on rounded heads with good luck before.

    If you are replacing the bearing assembly and axel assembly I'd use the torch and heat things up a might. I'd stay away from the ball joints unless you are replacing them also. I've been having to replace my ball joints at about 230,000 miles but have many that are over that.

    Don't buy the new Cardone axles. They are made in China. The Cardone rebuilts are done in Philidelphia I believe.
    I failed with the stud remover sockets, even after applying torch through the rotor vents.

    Already tried the torch as I assumed I was replacing bearings and axle assemblies. The boots on the lower ball joints are cracked, so they're due.

    Thanks for the info on the new Cardone axles.; I'll go with the remans. Might as well do it all while I'm in there.
    1999 Chevy Suburban K2500 4x4 w/ 6.5TD 190K miles. 4L80E and 3.73 rear gears. HD lift pump, ATT, Heath HO injectors, 4" Diamond Eye Turbo Back exhaust, Warpspeed x-over, deleted soot trap , D-Tech pmd behind bumper, Heath programming for ATT, Pillar mounted gauges: EGT, Boost, Tranny Temp. Replaced IP at 130K. HID light conversion with All-4-On-Hi. Forged Alcoa wheels.

    My son's 1994 GMC Suburban K2500 4x4 w/ 6.5TD 243K miles. 4L80E and 4.10 rear gears. Buddy 4 position tune. Rebuilt Bosch injectors and new Duraterm glows. HO water pump with Dmax fan, HD fan clutch and new AC Delco 195 T-stats. Diamond Eye 3" Downpipe and 4" exhaust, deleted soot trap. Warp speed 2.5" mandrel bent crossover. D-Tech PMD mounted behind the bumper. Pillar mounted gauges: EGT, Boost, Tranny Temp. Rancho 9000 shocks. Rebuilt front end and steering box tightened. Forged Alcoa wheels.

  15. #15
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    Since they are being replaced can you just cut the rotors out of the way without heating things up to much or blowing sparks where you don't want them?

    I'd heat the bearing assemblies red hot and then hit the bolts with Sea Foam and give it one last shot. If you still have a stud socket that will grip the heads

    Do you have the tie rod pulled off? That allows you to turn the steering assembly further for easier access.

    I also took the shock loose at the bottom.

    If you get in a good position and have a small cutting tip for your torch you can surgically remove the offending bolt heads.
    Last edited by jrsavoie; 09-26-2010 at 11:35 AM.
    98 GMC Suburban 2500 6.5 4x4 235,000 mi, FS2500, new timing chain, gears, Fluidamper & remote PMD, braided stainless oil cooler lines

    96 GMC 6.5 Suburban 1500 4x4 240,000 mi; Amsoil bypass & remote transmsision filters
    new timing chain, gears, fluidamper & remote PMD, braided stainless oil cooler lines

    95 Tahoe 2 door 4x4 6.5 240,000 mi;
    Stainless mandrel 3" exhaust, Amsoil Bypass filter, new timing chain, gears, Fluidamper, transmission, 3.73 rear end & remote PMD, braided stainless oil cooler lines

    1989 GMC Sierra 2500 2wd 5 spd get-rag trans had 108,000 mi. in 92 when the odometer broke. 7-800,000 miles on the truck. Installed a GM crate 6.5 non-turbo & FS 2500 in 2000 about 400,000 miles on the motor
    new timing chain, gears, Fluidamper & IP
    locked up and sold.

    95 Chevy C2500 xtra-cab 2wd 6.5 240,000 miles, remote PMD

    91 international 4700 low pro, spicer 6 speed, DTA 360 with 18' van box 500,000 miles plus.

    NRA Life Member for over 30 years
    Vote Freedom First

    1994 chev K3500 crew cab SRW 5 speed 4x4 230,000 miles
    PMD with heat sink. FS2500 bypass filter, The engine oil cooler lines are not leaking, Knock wood

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