I replaced my rear rotors/pads over the summer but kept the parking shoes as my parking brake was working fine. I had a very difficult time getting the old rotors off. They separated from the hubs no problem but were hung up on the parking brake shoes. After trying to finagle the rotors off, I finally said screw it and stuck a long screwdriver down in where the rotors were getting hung up on the brake shoes and pried and cranked all around the rotor, figuring if I mangled the brake shoes I'd just have to deal with the damage. Well, the rotors came off with some forceful prying in the right spots.
Putting the new rotors on I don't remember having any real difficulties and the parking brake still works fine despite the abuse the shoes received. Maybe you could try to lever down on the brake shoes with a screwdriver if you only need 1/16"-1/8" to fit the new rotor. Or you could take the rotor off the pass side, take a picture of your e-brake setup, and then check to see if you have identical placement of e-brake parts on the driver side. Also, would the new knuckle install have any bearing on the fitting of the rotor (in my head I can't really visualize the knuckle with respect to rotor)?
2007 XC70, 206,000 miles
2002 V70XC, 130,000 miles, parts car
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