I stand corrected and deleted my misinformation about the 7" disc and flange. I only have dealt with Cooper S and 8.4 disc brakes. I didn't know that a 7" disc brake set up was a little convoluted.

Yes they can be a real pain in the A$$ to remove. I recently took apart a set that has been sitting for decades that go to my 997 Cooper so a friend can machine drum type flanges to use on his 7 inch discs. The early 997 and 998 Cooper 7 inch disc drive flanges are very similar to the drum type in that the drive flange slides thru the bearings and then the CV joint slides into the drive flange. The bearings in the hub ride on the drive flange like that of the drum whereas with 7.5 inch discs they ride on the shaft of the CV joint and the splines are on the end of the CV joint where they go thru the drive flange and then ultimately tightened up with the nut. The splines on the 7 inch and drum CV joint are much longer and there is no smooth surface for the bearings to ride on since they ride on the drive flange itself.

Removing the drive flange is definitely a chore as often the bearings seize/stick to the drive flange. once off the mini and CV joint removed I sprayed penetrating oil (deep creep I think) into each end of the bearings where the shaft goes thru. On the inside of the hub where the CV joint slides thru there is a spacer on both the disc and drum type. Often it stays on the CV joint itself but I have had it stick in the hub. If it is still in the hub remove it. Basically it creates a surface for the inner oil seal to ride on.

Once the spacer is removed if it did'nt stay on the CV joint (every one I have done usually stays in the hub) you will be able to see the end of drive flange shaft where it slides thru the bearing. After soaking for awhile I have mangaged to get them out by using a wooden dowel or in most cases the end of a wood handled hammer and using it to place on the shaft and then hit the other end to push them out. The wood wont damage the end of the shaft. Just make sure it is small enough to slide thru the bearings but big enough to sit on the end of the flange. You dont want to be pounding on the bearings. Just the shaft. It should break lose from the bearings and come out. I have had to hit it back and fourth (in and out) a few times to get it loose and come out. Sometimes they barely move and hitting it back into the hub helps brake them free. 99% of the time there will be a lot of wear from the bearings on the shaft and very little from the spacer between the bearings in the hub. Once apart you will see what I am talking about. Obviously dont go putting them in vise and using a sledge hammer to puond on the darn thing. They should pop out just sitting on your bench and hitting sideways.

As I am sure you are aware parts arent easy to find for the early 7 inch discs. New disc rotors are available from Minispares but the drive flanges are not and finding a good usable one let alone two is not easy so take care not to damge them whilke trying to remove them. Don't hit them with a hammer without a piece of wood between the flange end and hammer.

If I can get them out of hubs that have been sitting for nearly 40 years you will get yours out too.

Cheers

Brian

I believe the drive flange is similar to the drum brakes - it extends through the wheel bearings. So it will need to be pulled through the bearings to get it off. the CV slides right out like a drum brake. The 7.5 disks are different as the CV rides on the bearings and the drive flange and rotor are splined to the end of the CV.

A MAPP's torch will give enough heat. Great cheap tool to make things all glowie.

I have 7” discs on my car and am trying to remove the discs to replace them and in prep for ball joints. For the life of me, I can’t figure out how to get the drive flange and disc separated from the hub. I already have the hub and disc assembly off the car, but the disc and driver flange just won’t separate from the hub. I checked my shop manuals and scoured YouTube and the forums for anything. Everything seems to be related to 7.5” discs and looks so easy. Is there something different with the 7” discs that I am missing.

Thank you in advance for any insight that anyone can provide.