Attention! If the brake discs are being modified, then the brake pads must also be replaced with new ones.
Removal
1. Mark the position of the rear wheels on the hub with paint. This will allow you to install the balanced wheel in its original position during assembly.
2. Loosen the wheel mounting bolts. The car must stand on its wheels when performing this operation.
3. Place the rear of the vehicle on jack stands and remove the rear wheels.
Warning! Jacking up the vehicle and placing it on stands may pose a risk of injury. Read the safety precautions in Chapter "Jacking up a car".
4. Remove the brake caliper, see the relevant chapter.
Note: The brake hose does not need to be disconnected from the caliper, and the brake pads do not need to be removed.
5. Secure the caliper together with the connected brake hose to the body so that the hose is not twisted and is not stretched.
6. Secure the brake cylinder piston in the caliper with a wooden block to prevent it from slipping out during work.
7. Release the parking brake completely.
8. Set the parking brake adjustment mechanism to its original position by unscrewing gear 1 of the mechanism with a screwdriver. The screwdriver for this operation is inserted into the hole of the wheel bolt (see illustration).
Attention! To set the adjustment mechanism of the parking brake shoes of the rear right wheel to the initial position, gear 1 should be turned with a screwdriver from the bottom up, and the left wheel - from the top down (see illustration 5.8).
9. Unscrew the brake disc mounting bolt on the hub and remove the disc from the hub.
Installation
10. Remove any rust, if any, from the brake disc flange and hub using a wire brush or sandpaper.
11 New brake disc. Remove the protective varnish coating with a rag soaked in solvent.
12 Install the brake disc on the hub and secure it with a new self-locking bolt to a tightening torque of 10 Nm.
13 Adjust the parking brake shoe adjustment mechanism by turning gear 1 to the desired position using a screwdriver. To perform this operation, insert the screwdriver into the hole in the wheel bolt (see illustration 5.8).
Attention! To set the adjustment mechanism of the parking brake shoes of the right wheel to the initial position, the gear of the mechanism should be turned with a screwdriver from top to bottom, and the left wheel - from bottom to top. The gear should be rotated in this way until the brake shoes are completely seated on the brake drum and the wheel cannot be turned. After this, the gear should be gradually unscrewed back until the wheel can be turned freely.
Attention! The gears of the adjustment mechanisms of the right and left brakes should be turned back by the same number of teeth.
14 Install the caliper, see the relevant chapter.
15 Install the brake pads, see the relevant chapter.
16 Install the wheels in accordance with the marks made during removal. Before doing this, lubricate the centering seat of the wheel disk on the hub with a thin layer of bearing grease. Do not lubricate the wheel mounting bolts. Replace rusted bolts with new ones.
17 Screw in the wheel mounting bolts and lower the vehicle.
Caution! Make sure that the brake hoses of the front wheel brake mechanisms are not pinched or rubbed when turning the steering wheel.
18 Tighten the wheel mounting bolts in a cross pattern to a torque of 110 Nm.
19 Apply the parking brake several times and check its operation. Adjust the parking brake if necessary, see the relevant chapter.
Attention! Press the brake pedal several times until you feel a strong resistance to pressing. When you do this, the brake pads are centered and they automatically set themselves to the working position.
20 Carefully break in the new brake pads. To do this, brake several times, bringing the speed from about 80 km/h to 40 km/h, and pressing the brake pedal lightly. In between, let the brakes cool down.
Attention! During the first 200 km of driving with new brake pads, avoid unnecessary braking until the car comes to a complete stop. Run in new brake pads carefully, taking into account the road situation.
Attention! Brake linings must not be thrown away with regular garbage, as the dust that forms on them is hazardous to health. They must be disposed of only at special points.
Attention! Make sure that:
- a) the brake hoses are securely connected;
- b) the brake hose is secured in the holder;
- c) the brake drive bleed nipples are screwed in;
- d) there is a sufficient volume of brake fluid in the expansion tank.
21. Perform a leak test of the brake system with the engine running.
To do this, press the brake pedal with a force of 200-300 N (20-30 kg) for about 10 seconds. The pressure in the system and, accordingly, the resistance of the brake pedal, should not decrease. Check all connections for leaks.