Just thought I would share this. I rotated my wheels & tires for the 1st time the other day at 26k miles. (tires still wearing fine) 2006 F250 FX4. The front wheels came off with no problem. Both rear wheels were stuck so bad that I had to use my biggest gear puller to hook thru the wheels, put pulling pressure on them & then beat on the back side of tire with a sledge hammer to get them off. Not sure why they were stuck but I know this would not have been fun trying to change a flat on the side of the road.
Mine did this too. I had to beat on the back side of the tire to get finally get them off. Then i filed the inside hub area of the wheel and lubed up the hub. Now each time I take them off an on I spray them down with WD-40. Like you i was really glad to find this out while doing a brake job instead of a flat on the side of the highway.
i think he means neverseize on the hub. it is galvanic reaction that causes this. the difference in metals is what causes the light white stuff you see when you pull of the tire. wire brush it when you have it off and apply a light coat of neverseize all around the contact area where the rim goes on. will be good then. i drive down 300 miles of gravel to get home and have never had a problem after doing this.
When I worked in a garage years back I would see this alot with customers cars. Cars with 20 to 50K with their alumimum wheels that have never been off. Heck somtimes I would just really wonder what the heck was going on. lol
I've had this happen too.... couldn't get one rear wheel off for anything.... buddy who used to work at a tire shop showed me a trick.
Take a small sledge hammer (I've used a 4lb with an 18" handle) and get under the truck. Now comes the tricky part. You want to swing the hammer so that the hammer head hits the tire sidewall first, but when the sidewall compresses, the hammer head also hits the rim. The sidewall takes a lot of the shock out of the blow, so you won't damage your rim, but the rim does get enough direct shock to break it loose.
As said above, never sieze, or grease between the rim and the hub will prevent this from happening again.
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