BRAKE ROTOR REPLACEMENT FRONT

Removal Of a New Front Pads & Disc

1. Lift the car and take off the wheel.
2. Press the brake piston back with a pair of Large Pliers.
3. Remove the two brake caliper securing bolts. Remove the front pads & Secure the brake caliper to the spring strut using a cable tie.
4. Remove the brake disc lock screw and take off the brake disc.

Thanks to Peter Myers for contributing to this FAQ!

Do not attempt to remove the rotor stay-screw with a star wrench; you will only get a lesson in frustration.

After soaking the screw with your favorite penetrating formula, apply a few well-placed taps to the screw using a medium punch and 3lb mallet or similarly heavy hammer. This rotor is almost seven years old, despite this the screw freed-up after only a few hits.

This screw is not torqued into the hub, it's merely there to hold the rotor in place and make it easier to mount the wheel without it shifting. When replacing there is no need to torque it down and it cannot come out since the wheel will cover it.

Installation Of a New Front Pads & Disc

1. Be sure to wash the new brake disc and check that the contact plane of the brake disc on the hub is free from corrosion and burrs etc.
2. Check that the area of the hub in contact with the brake disc is not corroded or dirty when the brake disc is fitted. Place the brake disc on the hub and tighten up the securing bolts using a locking compound. Tightening torque should be 4 Nm (3 lb.ft ft)
3. Fit the brake caliper, the brake pads, apply thread locking compound and tighten the bolts.
4. Re-install the wheel. The Tightening torque will be 117 Nm (86.6 lb.ft ft) - light alloy wheels & 100 Nm (74 lb.ft ft) for pressed steel wheels

5. Lower the car and stamp on the brake pedal to force out the brake pads (make sure you do this because you will have no brakes for a small time until the pads make contact with the disc. Test drive the car and check the brake operation