I'm in the middle of replacing my rear rotors. there appears to be a allen screw that needs removed to get the rotor off... I've stripped the screw even though there was half a can of PB blaster on it... any advice to get the screw off? Any advice on getting a new screw? do I really need a new screw? There was only one screw on it to begin with.

I used a 4mm allen wrench to go at it - think that was the right size - and it still stripped out. Any advise so I don't screw up the other side?

02 S40, 4 banger, turbo, FWD

 

Finally got it by hammering in a t27 star bit. Now can't get the rotor off. Pretty sure it hasn't been changed in 215k miles

 

Finally got the rotor off with enough pounding with my rubber mallet. Worked fine. The other side was easy once I figured out all of the tricks on the first side.... usually the case (I had changed the break pads a few years back and remembered I needed the break piston compressor thing for the rears.)

Just in case someone else ends up doing this job
I did find on the other side that the set screw was 4mm and I was able to get it off easily with some PB blaster and a quarter inch driver with a 4mm allen bit. DO NOT use a 5/32"... it's close - but not close enough - the metal on the screw is too soft for a 5/32". Also be sure to clean out the screw of debris before trying to get it off.

 

And heat. A quick blast from a propane torch can work wonders.