http://s139.photobucket.com/albums/q291/Calibra_se8/Project%20Cally/changing%20brakes/This is a guide I have compiled to help everyone change their brake pads and discs safely.
Before taking your brakes apart, please make sure the pads and discs you have just bought are the same, as I have done this and it is not fun when you have thrown away the old ones to find the new ones don't fit
Also please make sure you have a 7mm allan bit or an 'L' shaped allan key, these are readily available from Halfords and the likes.
First up you will need the car jacked up with the road wheel removed, it also helps to stick the car into reverse gear for removing the small screw that holds the disc to the hub.
First up, it always helps to remove the lid from the brake fluid resevoir for pushing the pistons back
Next step is to prise away (using a screwdriver and pliers) the spring clip at the front of the calliper
Next prise off the dust caps shown by the arrows
Now you need to push the piston back into the calliper, otherwise the new pads will be too thick and will not fit back on, using a long flat bladed screwdriver, push it between the disc and the pad nearest the piston (the pad closest to the engine) If there is not enough room tap it in with a hammer. Remember this is ok as the pads and discs are being replaced.
Then when the screwdriver is inbetween the pad and the disc lever the screwdriver backwards and forwards until the pad is as far away from the disc as it will go.
Next up undo the upper and lower (Slider Bolts) using your 7mm allan bit or L shaped Tool.
And withdraw the calliper assembly remembering to tie it up and not leave it hanging by the brake hose as this could cause damage to it.
Now undo the two bolts/nuts that retain the brake calliper carrier (they are sometimeas different so I cannot specify what size they will be) and remove the carrier
You should now just be left looking at a brake disc, you will see a small screw, usually a phillips screwdriver fitment, undo this and withdraw the brake disc, the brake disc may be hard to come off, give it a few light taps with a hammer and watch your feet
Now before fitment of the new disc, give the hub a good wire brush and a clean down with some brake cleaner, this will help the new disc mate flush to the hub and stop and brake distortion.
Also put some copper grease on there, it will make the disc nice and easy to get off next time
Now with your new disc (I am using my old ones just as a guide) get the brake cleaner and a cloth and go over your new disc with it, the reason for this is most new discs come with a protective layer on them to stop them corroding in storage.
Now fit the disc to the hub, and replace the screw to hold it on
And replace the brake calliper carrier
And now for your new pads, first up discard the old ones, the one that is on the piston has little spring clips to hold it in, just pull the pad and it should unclip
Give the edges of the calliper where the brake pads were a good wire brush aswell, again for a flush mating surface. Then put some copper grease on the back of your new brake pads
The pad with the spring clip on it needs clipped into the piston, just push the two side clips in and push the pad in as shown in these photos. The arrows point out the two clip ends you need to push in
And mount your other brake pad on the carrier where it would be if the piston was fitted, the picture shows an outline of where you should put the pad (the black and grey drawing represents the new pad)
Now position the calliper back on the carrier until the two brake pads sit in their retaining slots and give the calliper a few soft thumps just to push it right onto the brake disc.
Now refit the calliper slider bolts with your 7mm allan key. It is recommended that you replace the bolts on your callipers and carriers but I must admit I have never had any problems fitting old ones again. This is of course your choice.
Make sure that you tighten the calliper and carrier bolts to the torque setting given in the haynes manual. (although I find that doing them up nice and tight works fine)
Now remember to replace the cap on the brake fluid resevoir
Refit the roadwheel and lower the car, remembering to give the road wheel bolts a tighten when the car is on the ground.
Once both sides have been done, give the brake pedal a few pumps until it is resisting you pushing, this is when you know the pads are touching the disc and the calliper is against the pads.
Last thing to remember is the brakes will need bedding in, so no heavy braking for the first hundred miles or so, otherwise you will ruin all your hard work and effort by warping the discs. Enjoy and any questions PM me
