How-To: Complete Brake Service

[rainierez]

TOC

Removing the Front Calipers
Rebuilding the Front Calipers
Removing the Front Brake Pads
Removing the Front Rotors
Removing the Rear Caliper
Rebuilding the back Caliper
Removing the back Brake Pads
Removing the back Rotors
Bleeding the brakes.

Obviously the first steps are to jack up the car and put it on stands. Make sure it is secure before doing any work.

This write up is meant to be instructional but not the end all. Different models have different bolts and sizes. Any work you do is done at your own risk. I can not take responsibility for mistakes or issues.

I decided to rebuild my brakes after feeling some sponginess and pulsing in the brake pedal. Also when I took the apart I found the Dust shields on all four calipers to be torn and in a generally piss poor shape.

JOB DONE!

 

[rainierez]

First I started by loosening the bolt that holds the Caliper to the shoe. I left it threaded in a turn or two. But you want it easy to remove once you pull out the banjo bolt. It will keep from making too big of a mess. You'll want to put a drain pan or some thing under you work to catch all the brake fluid that will leak out.

Loosen and remove the banjo bolt, be careful not to lose the sealing washers and keep the bolt and washer clean.

Banjo bolt is just past the bleeder valve

Banjo bolt removed

Pivoting the caliper up and clear of the pads and shoe, push it away from you and off the shoe's pivoting shaft.

 

[rainierez]

Rebuilding the Front Calipers

First remove the dust shield. Just tug on it. If need be you can you a screwdriver to wedge in there just a bit to get the first part loose then pull the rest.

Now clamp the caliper down. Put a rag or two to catch the piston. It will move slowly at first then will pop out at the end. Put you air chuck in the hole where the banjo bolt was and pulse air pressure until it pops out.

Now just inside the bore there is a black square gasket. this needs to be remove and replaced. While it is out please clean the bore and gasket groves throughly with a clean lint free cloth.

Also clean the Piston

Once it is clean coat the piston and bore with brake fluid and slide the piston into the bore. Make sure it is straight and then apply even pressure with a C-clamp and a brake pad.

<Picture Coming>

When you get almost to the end stop and put the new dust shield in place. I always start at the side you can't see. it is easier to start there because the finish is the hardest part so being able to see what you are doing is key. Anyway use a screwdriver (careful not to cut or tear the new shield) or a harder zip tie to push the Dust shield into the caliper body first then set it in the grove on the piston.

<Picture Coming>

 

[rainierez]

Removing the Front Brake Pads

First remove the Spring clip that is going from pad to pad. Each pad is just sitting on the rails of the shoe at each end. The clips are only there to reduce rattle they arn't really keeping the pads in there tight. Pull then away from the rotor and out.

Note: If you are not planning on rebuilding the caliper you can leave the caliper attached to the shoe just flipped over on the pivot arm

 

[rainierez]

Removing the Front Rotors

There are two bolts that hold the shoe to the hub. they are 17mm and are on there pretty good. I had a breaker bar to get them loose. would not want to do it with just one box end wrench. Anyway remove both bolts and pull the shoe out.

Now rock the brake rotor towards you over and off the lug bolts

Now get your self to your local auto parts store or mechanic to get those rotors resurfaced.

 

[rainierez]

Removing the Rear Caliper

Again Loosen the bolt holding the caliper to the shoe. Leave it a few turns in so you can loosen and remove the banjo bolt.

Now remove the banjo bolt and brake cable. then turn the caliper out. Also don't forget to place your drip pan under your work.

Now pull the clip off the parking brake cable. then remove it from the bracket first then the part of the caliper it pulls on.

Push the caliper away from you off the pivot shaft from the shoe.

 

[rainierez]

Rebuilding the Rear Caliper

Start by removing the bolt that covers the parking brake adjustment.

This can be done by one person but two would be helpfull. Use an allen wrench and turn clockwise while putting air pressure in the banjo bolt hole. Remember to put some rags in the caliper to catch the piston.

Once it is out, remove the square gasket and clean the bore and piston. Insert the new gasket into the grove of the caliper bore. Cover the bore and piston with brake fluid then reinsert the piston. Push with one hand and turn the allen with the other. It will slip back in easily.

Before the piston is all the way in fit the dust over on the piston and put it into the grove on the bore of the caliper.

Make sure to cover the adjustment hole back up. Now you have a rebuilt Caliper.

 

[rainierez]

Removing the Rear Brake Pads

The brake pads like the front are just sitting in rails on the shoe. Just slide them away from the rotor on both sides.

 

[rainierez]

Removing the Rear Rotors

Again Same as the front. There are two bolts holding the shoe to the hub. Remove those with a braker bar or two box end wrenches.

Then rock the rotor forward over the Lug bolts. Now go get the rotor resurfaced with your front ones.

 

[rainierez]

Bleeding the Brakes.

Now really I can't do to great of job explaining how to bleed your brakes with just pictures. It helps to watch a video of someone doing it do a quick search on youtube. Now keep in mind if you just rebuilt the calipers then there is NO fluid in the calipers and little in the lines so you may need to have someone pump them for a while before the fluid comes out.

A few tips:
- Go in order. RR, LR, RF, LF. Start with the farthest from the brake booster and work to the closest.
- Maintain the method. "Press the brake" then open the bleeder, let it flow till it stops, Close the bleeder, "Lift" Repeat.
- Use a clear plastic tube with the other end in a cup of brake fluid. That way you can see any air coming out and it keeps it from sucking air in.

 

[wildo]

Lookin' awesome man! Since the MP3 has the same calipers as the P5 and ES (apparently) you may ask a moderator if the how to should also live in the P5 section. Not sure on that one... At any rate- awesome pics. Can't wait to get the DIY Clunk Fix brackets on there!

 

[rainierez]

Yea I think this is in the wrong place. This need to be moved to the MP3 and P5 sections. It's just that there was no MP3 How-to So I put it here. Moderators? Admins? help

 

[rainierez]

For some reason it is just not in any category now Can an admin help me get this in the right forum.

 

[JCell]

where can you buy the gasket for the caliper?

 

[rainierez]

I bought mine at O'riley auto parts

 

[JCell]

thanks man, i cant wait to do mine