DIwhy: Brake Disc Replacement

[Boban]

Disclaimer: The following is provided as a GUIDE ONLY, and neither myself nor Ozhonda take any responsibility for the outcomes of someone else doing the following. You follow these steps at your own risk!


Aim:To replace your old tired discs for some new shiny ones, maybe they are old, cracked, overused, below the legal limit, or just for the wank factor, and/or put in some new pads *optional
Required:Tools: Jack, Jack Stands, Wheel Brace/rattle gun/breaker bar (your choice), Phillips Head Screw Driver, Impact Driver with Philips Head Bit, Multi-grip pliers *optional (or whatever you want to push the caliper piston back in), 10,12,14,17 mm sockets + ratchet, 10mm spanner, Zip Ties
PARTS:new discs and pads *optional,
Steps:
1. Before i do any work on brakes, i always undo the reservoir cap and put a rag under/around it to stop any spills. Reason being, when you squeeze the piston back in it lets the air escape as the fluid is building up in the bottleavoiding any unnecessary pressure buildup. I know not everyone does it, but i do.
http://img17.imagehosting.gr/out.php/i856496_imgp0412.jpg (http://imagehosting.gr)
REAR
2. Let's assume that we all know how to take off the wheels, so loosen the nuts, jack it up, stick stands underneaths and take he wheel off, simple :thumbsup:
http://img17.imagehosting.gr/out.php/i856494_imgp0410.jpg (http://imagehosting.gr)
http://img17.imagehosting.gr/out.php/i856497_imgp0413.jpg (http://imagehosting.gr)
You can see 2 philips screws that are holding the disc on, so they'll have to come out in due time.

3. First thing to come off is a little dust plate thingy. It's held in by 2 10mm bolts, one up top which you'll see straight away and one in between the hub and the strut, bit of a PITA to get to but you can do it with a 10mm spanner, none of my ratchets could fit in.
http://img17.imagehosting.gr/out.php/i856498_imgp0414.jpg (http://imagehosting.gr)

4. Let's ignore the overspray for a moment and concentrate. The rear calipers are held in by 2 12mm bolts, undo them and put the caliper somewhere out of the way, i zip-tied it to the spring
http://img17.imagehosting.gr/out.php/i856521_imgp0415.jpg (http://imagehosting.gr)

5. Now you can see 2 14mm bolts holding in the caliper bracket, remove them
http://img17.imagehosting.gr/out.php/i856522_imgp0416.jpg (http://imagehosting.gr)
Should look something like this
http://img17.imagehosting.gr/out.php/i856523_imgp0417.jpg (http://imagehosting.gr)

6. Now remove those 2 Philips screws holding in the disc. I used an impact driver to loosen them and than just undo them with the screw driver
http://img17.imagehosting.gr/out.php/i856524_imgp0418.jpg (http://imagehosting.gr)

OLD vs NEW, compare and laugh
http://img17.imagehosting.gr/out.php/i856525_imgp0419.jpg (http://imagehosting.gr)

7. Wipe the rusty hubs with some wd40 and a rag, if it's really bad use a wire brush to get as much off as possible. Put the new disc on, tighten the 2 Philips head screws and reinstall everything else.
http://img17.imagehosting.gr/out.php/i856526_imgp0420.jpg
http://img17.imagehosting.gr/out.php/i856527_imgp0421.jpg
First the caliper bracket, then the caliper, then the little dust shield and finally the wheel, Repeat for the other side :thumbsup:


FRONT
1. Loosen the nuts, jack it up, put stands underneath and take the wheel off
http://img17.imagehosting.gr/out.php/i856528_imgp0422.jpg (http://imagehosting.gr)
http://img17.imagehosting.gr/out.php/i856529_imgp0423.jpg (http://imagehosting.gr)
Same deal as the rears, 2 philips head screws holding the disc in

2. The front calipers are held in by one 12mm screw, undo and slide it off the greasy pin thing, don't make a mess of everything like i did. Again i just zip tied the caliper to the strut and out of the way.
http://img17.imagehosting.gr/out.php/i856530_imgp0424.jpg (http://imagehosting.gr)

3. There are 2 17mm holding the caliper bracket, in, undo those
http://img17.imagehosting.gr/out.php/i856534_imgp0425.jpg (http://imagehosting.gr)
Should look something like this
http://img17.imagehosting.gr/out.php/i856535_imgp0426.jpg (http://imagehosting.gr)

4. Undo 2 Philips screws and take off the disc
http://img17.imagehosting.gr/out.php/i856536_imgp0427.jpg (http://imagehosting.gr)
OLD vs NEW
http://img17.imagehosting.gr/out.php/i856537_imgp0429.jpg (http://imagehosting.gr)

5. Wipe the rusty hubs with some wd40 and a rag, if it's really bad use a wire brush to get as much off as possible. Start reassembling now, first the disc, do up the screws, then the caliper bracket (good time to put on new pads), then the caliper and finally the wheel.
http://img17.imagehosting.gr/out.php/i856538_imgp0430.jpg (http://imagehosting.gr)
http://img17.imagehosting.gr/out.php/i856564_imgp0431.jpg (http://imagehosting.gr)
http://img17.imagehosting.gr/out.php/i856565_imgp0432.jpg (http://imagehosting.gr)
And that's it.

Other comments: Guys and Gals, since the brakes are a major safety component of the car, please do not do it if you are uncomfortable with this. However, if you have ever changed your brake pads, this will be pretty straight forward to you.
So happy modding and
http://img17.imagehosting.gr/out.php/i856566_imgp0435.jpg (http://imagehosting.gr)


On a final note, BIG thanx to Yonds @ JDM Yard for supplying the discs in record time, way cheaper than local parts stores and about the same waiting time, and also my younger brother who let me raid his work van for all the tools.:D

[aaronng]

You forgot to remove the rust from the hub after removing the old discs using a wire brush and some WD-40. The rust can cause the new disc to go off balance when the rust expands as the metal rusts.

Also, you should clean the new rotors with brake cleaner. They come from the factory with a thin film of oil to prevent rusting before being sold.

[Boban]

Edited first post, thanx for the tip aaron, i did wipe the hubs before putting the new rotors on with a rag and some wd40, but i didn't wipe the oil off the new discs when i put them on. It looked pretty funny when i went around the block and they started smoking, ppl at the lights were like WTF is going on is your car on fire :D, all good now

[aaronng]

Get all of that rust off. But it won't kill you if you don't. You just get vibrations through the steering wheel. :)

[NSPYRE]

heard somewhere that pads and rotors have to be broken in by different methods? pads have to be broken in by hard rough braking to prevent them glazing and discs are to be done smoothly to prevent them warping. so wat is usually done is the pads are put in first with the existing rotors and mashed up well. chuck out the old rotors and have the new ones put in.

is this still the case or can they just be changed together and everything be all good?