I needed to replace my rotors and pads, they were making a god awful noise...and I had left it too long.

The drivers side came off brilliantly, but the passenger side won't budge. Incidentally the passenger side was much worse than the drivers side, and I'm wondering if that had anything to do with the bolts being much more difficult to get off.

Any ideas about what I can do to make this easier?

BTW Subaru is fucked. There are three different possibilities for the size of disc on my car...according to the guy at the parts store, depending on what month the car was built, Subaru used different calipers and discs. I guess they used parts from different suppliers, depending on availability.

IF your local subaru dealer is not helpful try and email subaru of dallas with your VIN and they should be able to help you out.
Also, Stoptech BBK >>>>>>>>>>>>>>>>>> OEM stuff

I always used impact wrench..., but some WD40 may help

and BBK kits are usually 1500+

...he doesn't drive a WRX/STi that sees regular track work, he doesn't need a frickin' stoptech kit.

Disc size shouldn't vary like that I can foresee different part numbers for different brands of suppliers (like maybe Brembo and AC Delco both make rotors for your car, for exmaple), but they should be interchangeable.

Try PB Blaster and the longest wrench you can find + a pipe on the end of it.

Three different rotor sizes is nothing, the S40 has 4 different sizes for the front!
http://www.ipdusa.com/Volvo-S40-2004.5-200...p-135-530-3159/

EDIT:Nevermind it's 3 as well. I saw 4 front rotors and only glanced at the sizes. You have my sympathy. I have no clue which size ours requires.

Well I fought it with some liquid wrench, a big assed wrench, and a pipe for a good 1/2 hour after posting...to no effect.

I got frustrated and decided to pay someone to get the mofo off for me, and drove it to a local shop, which proceeded to brake off the bolt heads, and felt so bad about it that they got them out and replaced them for free.

Following that I finished the job at home. God damn, all told that was a five hour job! But boy does it feel good to have dome that mostly my self.

The possible disc sizes were 255mm, 270mm and 275mm...all for the same model and year. Mine turned out to be the 275mm discs. Also, I don't know what the originals were made out of, but I would guess the replacements were about 75% of the weight of the ones I took off. I was actually kinda impressed with the front brakes, they were floating calipers, but had two pistons...I always assumed they were single piston calipers, considering the base model nature of my car.

I never said he needed a stoptech kit .. i just said they are better than OEM. I just had one of those i wished i had the money moment to get those tasty goodies moment when i typed that.

your best off getting a semi metallic pad from like hawk pads and a nice strudy set of brembo blanks.
that should give you the brake feel your looking for, the pads will be a tad louder though.

Money is really tight with the new kid and all, so I just got the after market equivalents of the cars original parts. I always think about getting the performance pads...but then I think about how they wear rotors faster, and think different.

Maybe I'll change the fluid to something more sporting...maybe.

Valvoline Synthetic brake fluid Costs like $6 a quart or something or even less if you get it on sale in Autozone or walmart. Worked very nicely on the race track too.