Brake Pad And Rotor Replacement

by: Passaturbonium


DISCLAIMER

Background:

IMPORTANT: Rusty made a good point, which is not in this how-to that I noticed in the Haynes manual. You can open the reservoir for the brake fluid to hold the extra fluid when you compress the pistons as described in this how-to or you can follow the Haynes directions which are listed following: To make room for the new pads, the caliper piston must be pushed back into the cylinder. Either use a piston retraction tool or a C-clamp. Connect a brake bleeding kit to the caliper bleed screw. Open the bleed screw as the piston is retracted; the surplus brake fluid will then be collected in the bleed kit container. Remember to tighten the bleed screw as soon as the piston is retracted to prevent air from being drawn into the system.

Tools needed:

  • 7mm Allen key
  • 17mm wrench/ratchet
  • 13mm wrench
  • 15mm narrow wrench (cone/pedal wrench?)
  • caliper retractor set
  • jack stand(s)
  • home-made caliper hanger (bent heavy coat hanger)

Parts needed:

  • 2 front rotors
  • 4 front brake pads
  • 2 rear rotors
  • 4 rear brake pads
  • Disc-brake quiet for backs of pad
  • Anti-seize for outside face of rotor, inside face of wheel, and on lug bolts
  • high-temp grease for slider pins
  • Locktite Blue for caliper bolts

(This brake job was done on 1999 B5)

FRONT:

Step 1 - Take off the wheel. Also open the brake reservoir. Sometimes when you retract the caliper it might overflow.
So put a rag around it also.

Step 2 - Take the tension spring off.
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Step 3 - Remove 2 black caps in the back of the caliper.
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Step 4 - Remove 2 bolts, use 7mm Allen
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Step 5 - Press against the rotor and caliper to loosen it.
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Step 6 - Slide off the caliper.
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Step 7 - Remove old brake pads.

Step 8 - Remove 2 bolts and bracket, use 17mm ratchet.
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Step 9 - Remove rotor, it should slide right off, if not use a hammer to tap on it here and there.
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Step 10 - Apply Anti-seize.
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Step 11 - Install new rotor.
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Step 12 - Reattach the bracket: torque to 92 ft-lbs.
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Step 13 - Retract the piston using big pliers or C-clamp.
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Step 14 - Apply brakequiet on the back of new brake pads.
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Step 15 - Apply brake pads, as shown in the picture.
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Step 16 - Slide the caliper on.
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Step 17 - Reapply the hex bolts, you need to torque these to 18 - 22ft.
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Step 18 - Replace the plastic caps.
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Step 19 - Replace the tension spring.
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REAR:

Note: You are going to need put something under front tires cause you can't have the E-brake on.

Step 1 - Take the wheel off. Also open the brake reservoir. Sometimes when you retract the caliper it might overflow. So put a rag around it also.

Step 2 - Unscrew the caliper bolts using 13mm wrench and 15mm to hold it in place.
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Step 3 - Pull off the caliper.
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Step 4 - Slide off the rotor, you do not need to remove the bracket, slide on new rotor.
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Step 5 - Retract the piston using either the tool or needle pliers. Screw and push clockwise.
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Step 6 - Apply brakequiet to the back off the brake pads!
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Step 7 - Apply brake pads.
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Step 8 - Slide on the caliper and screw in the bolts: torque to 22 ft-lbs.
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DONE

PLEASE READ!!! Make sure you pump your brakes few times before driving!!! They should go down all the way the first time you step on them. Just pump them up.

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