How to change wheel discs

[paulburrell]

Anyone undertaken this task themselves. In particular I need advice on how to release the brake line on the front struts in order to remove the caliper and then replace the discs.

Also anyone know whether the Wokshop Manual is available on CD and if so where I might buy a copy???

Steve :D

[ar38070]

You do not have to remove the brake line from the caliper. You just undo the two bolts holding the caliper to the wheel carrier and then suspend the caliper with some wire while you work on the disk.

[LVDell]

Personally I use a bungee tie down and hand it from the shock tower.

[Stefan]

Here are the basic steps...

1) Remove the wheel

2) Remove the caliper bolts

3) Pull the caliper off the rotor

4) Prop the caliper in such a way that it isn't hanging from the brake line (easiest to use picture wire)

5) Undo the screws holding the rotor in place (very easy. They don't have much torque)

6) Pull off the old rotor

Reverse instructions to get the new one on. Make sure to torque the caliper bolts according to spec (don't have the number with me). To get the caliper onto the new (presumably thicker) rotor you may have to push the old pads out a bit and wiggle it a bit to get the pads around the new rotor.

Good luck.

[LVDell]

Just do a brake bleed while you are in the process and you can easily move the pads back BEFOREHAND or take the pads out BEFOREHAND and either replace if time for new ones or just reinsert after the install.

[paulburrell]

Thanks guy's it's just like the process on my old 968CS and 993 C2. That's very reassuring. If I read you all correct, after the two cheese head bolts have been removed, there's enough movement in the brake lines to be able to move the caliper clear of the disc and thereafter removing the disc. On my other cars, the bracket on the strut where the brake line is clipped was cut so that the lines could easily be slipped free and extra space created to move the caliper around.

[ar38070]

Actually you are right. There is a bolt (10 mm head) that holds the rigid part of the brake line to the wheel carrier. Just follow the brake line from the caliper and you will find it. Remove that also then the flex part of the brake line allows you to move the caliper away from the disk.

You may have to squeeze the pads back away from the rotor and remove the pads first depending on how much of a lip you have on the rotor.

[David Bu]

All well and good, but the disc [rotor] won't come off - it appears to be free, but only one one side. There are two additional holes withtreads - what are they for. Should the rotor come off easily, or are these two threaded holes designed B) to effecively lever the rotor off??

[Loren]

If a stuck brake disc cannot be removed by gentle tapping with a plastic hammer, evenly screw hexagon-head bolts into the two M8 threads of the brake disc thereby pressing off the disc.