Well I finally got my 9 year old rotors off! ( the car only has 53k miles but has seen 9 Michigan winters) One rotor was very difficult to remove and the other was near impossible. I had to resort to using a 7 ton puller and a MAP gas torch and it still came off in pieces.
Two questions that I have...

1- After using a lot of heat on one rotor did it affect the bearings? I cant repack them because I believe the hub is sealed.

2- When I compressed the caliper piston the seal around it pops out a bit and will not allow me to push it in, it just pops out on the other side of the piston. This is happening on both calipers I'm afraid the rubber seal will get between the piston and the pad.

Thanks for reading my post and I'd appreciate some feedback!

 

1) hub - hard to say - they will take a fair amount of heat, but about all you can do is replace the hub IF you have problems (you are correct they can't be disassembled)

2) the seal is important to keep dirt etc. from chewing up the rubber, the caliper bore and the piston etc. - they can be tricky to get back into position, and one often has to use all 8 fingers to get it to kinda pop back into position. If it just will not go back flush with the piston, you should just replace it.

 

At 53,000 I'd replace the hubs while I'm down and dirty, cause you know they will need changed eventually!
As for the calipers, rebuilds are fairly inexpensive, for safety change them

 

The OEM hub assemblies are a crap shoot as far as longevity, members have had them "go" at 25,000 miles, and some "Mega Mile" HHR's are rolling on hubs with 400,000+ miles and counting.

Heat + a 7 ton puller to get the rotors off, that in my book is probably going to guarantee hub failure down the road, how far down the road...well that's a good question.

And ditto to whopper's comments on the calipers.

 

On your caliper I think what you are seeing in air that's trapped behind the dust seal.

Use a small pic tool or screw driver to pull the seal away from the piston and let the air out then it should fit flat.

 

Thanks for the help guys! You were right about air being trapped behind the seal, came right out with a pick.
This forum is great!
I

 

my factory rotors had 112k on them when i had them replaced today by my local shop. got new pads and rotors. i have owned the car since may of 2011, it had 34k when i bought it, and now i have 112k. needless to say, i do alot of driving. mostly highway. this is only the 2nd set of pads, and the first set of rotors ive had to put on. so far so good. :)