where is life going
AO Silver Member
Join Date: Sep 2003
First, If it goes wrong, don't blame ME!!!
But the proceedure is as follows - no special tools needed, except torque wrench.
jack up and wheel off, loosen lid on brake fluid resevoir.
At the wheel, pull caliper body toward you to release clamping pressure by brakes, careful brake fluid going back to resv does not make it over flow (use a syring to remove some if necessary, watch paintwork!).
Remove the caliper spring (pliers and pull), and undo any brake pad wear wiring etc. Undo the 2 bolts holding the caliper to its mounting bracket - you will need an open ended spanner to hold the guide pins so they dont rotate when you do this, remove caliper and pads. Dont let the caliper hang on the hose at all, tie it up or sppt it, the hose is delicate!
Undo the 2 bolts securing the caliper mtg brkt to the hub carrier (they are very tight) and remove it. undo the disc securing screw. Then use a rubber mallet or similar to tap the old disc off (turn it and tap firmly from behind at various points til it comes off).
clean hub etc up, and smear TINY bit of copper grease on hub where disc mounts. CLEAR PROTECTIVE OIL OFF NEW DISCS WITH WHITE SPIRIT OR SIMILAR - very important. Mount disc, secure with screw (all torque setting for a 2001+ 156 2.0TS below).
Refit caliper mtg bkt, and caliper (hold guide pins as before (thinish 15mm spanner i think). Also a good idea to fit fast road/new pads while its all apart.
Connect all wires, put spring back (is a bugger to fit, but just pliers and brute force needed).
put wheel on, do other side, check fluid level then bed in as below
Torques all in NM
Caliper guide pin bolts 5nm
Caliper mounting bracket to hub bolts 16nm
Disc securing screw 1.3nm
Wheel bolts matt finish 9nm, or if chrome finish bolts then 10nm
Bed in basically
30mph - 0 V light braking 5 times
40 - 0 med light braking 5 times
50 - 0 med braking 5 times
60 - 0 med heavey 5 times
70-0 heavy 5 times.
Allow to cool completely and repeat.