Well here what I tried so far:
-sprayed around axle hub and stud holes and back of back of rotor with 1/2 can PB Blaster
-put bolt in 2 screw holes to pop off rotor like haynes suggests, stripped holes out!
-ball pean hammer to try to knock the rusted rotor loose
-air hammer to try to knock the rusted rotor loose

Anybody got any more suggestions???

I'm hoping letting it soak overnight will work....but I might bust out the 5lb sledge!

I've had rotors rust-welded before, but this is the worst I've I ever seen.

If you plan to replace the rotors anyway the 5lbs sledge might not be a bad option, just remember to give love taps to both sides of the rotor so that it comes off evenly to prevent broken/bent wheel studs.

if you think that you want to save the rotors, try the same using a wood block or a dead blow hammer.

**NOTE** (I did this) DO NOT try using the "loan (break) a tool" puller from Auto Zone that you secure onto the wheel studs and tighten onto the end of the axle. If you do this you will only press out the axle from the hub (not good).

Sorry I am probably not much help. Just thought I would offer as much "DO NOT" advise as possable, I do not remember what I did to remove the one that was stubborn for me.

get a large rubber mallet. go slowly tapping around the rotor. Gradually increase the swing momentum till you are full on. Continue beating around the rotor untill it comes off.

I know you are going to sit there and say, i already beat on it... Been there played that card. Travis gave me the rubber mallet and said don't stop till it comes off.

since then, i've seen plenty of prolematic rotors that just take some time with the rubber mallet.

No need to save the rotors, they're really bad. Especially now with a bunch of ball-peen hammer mark in them!

I'll try the rubber mallet, and when I get sufficiently pissed I'll try the sledge!

gsxracer80
Thanks for the heads up on the "puller" deal, I was thinking of going with something like that.

A sledge will get the job done but can cause damage to the wheel bearings as well. Just be careful.

if all else fails u could remove the entire hub and try dropping it studs down on something decently hard.......

Got it off finally...after I knocked the head off my rubber mallet.

I decided to knock all the studs out of the hub. Was able to squirt some more PB Blaster into the studs holes to get some more penetration. With the studs gone, the rotor had some more room to move. A few well placed hammer strikes finally got it off.

Discovered now one of the tie rod ends is bad. Guess I swap both of them before I finish up.

Thanks for the help guys, hopefully the stud removal trick will help someone else down the road.

I know your problem has already been solved, but I have a little something to add. I've had good luck with rusted parts by using heat. A MAPP torch on the rotor for a little bit will do wonders. The heat expansion can often break the rust bond.

heat does work wonders. that's why i believe in the new 'warming' ky.