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-   -   DIY: Cross Drilled Rotor Brake Install! StepByStep (http://forum.e46fanatics.com/showthread.php?t=410638)

5speedsteve 10-13-2006 09:56 AM

DIY: Cross Drilled Rotor Brake Install! StepByStep
Yea! More DIY's

This Ones Pretty Easy its 5 bolts per brake and 1 Spring

2 16mm (the caliper to hub)
2 Small Allen Keys (the outer caliper to inner caliper)
1 Smaller Allen Key (the front of Rotor to Hub)
1 Spring (holds in outer pad)
1 Hammer (hit the rotor with the ball side of the hammer)
4 New Zimmerman Rotors
4 New sets of Pads
2 New Brake Sensors (or you can do what I did and splice the wires together)

Car on Lift (you don't need a lift to do this)

Fronts First...Wheels Off

Take out the two 16mm Bolts There on the back of the Caliper

Pry the caliper off (feel free to hit the rotor with a hammer to help loosen things up)

Hit the rotor with a hammer a few times right where this bolt is and then loosen the bolt

Rotor comes off and clean up the hub

New Rotor Goes on and tighten the bolt (see that was easy)

Take the pads out of the caliper and slide two pieces apart (stationary section and sliding section)

Take the two Allen bolts off

Clean em up on the grinder

MMM yummy

Put the caliper on with the two 16mm bolts.

Push the piston back into the caliper (there is a special tool for this but I'm not that special.....so big wrench really does it just fine)

Now put the pads in that piece and put it in place

Now your fresh allens can go back in (theres lil black caps that cover these bolts)

MMM passenger side done!

5speedsteve 10-13-2006 10:00 AM

I forgot to Mention the spring goes on the outside you see its there^^^^

The Driver Side is the same Procedure..!....Except theres the Sensor

You can replace it to make your light go out if its worn down really low
or you can cut off the end and splice the wires together. I didn't order one but I probably will later.


5speedsteve 10-13-2006 10:11 AM

Now the rears are basically the same.

To help get the rotors off I hit them first and lossend the small allen bolt before I took the caliper off.

Now take out those 16mm bolts.

I hit my wrench with the wood part of a hammer to break them loose

After you pry off the caliper Now you can take the rotor all the way off

Clean up the hub.

WTFF okay the e-brake is a drum brake whatever. So you have to adjust the auto adjuster to make it small...Theres a tool to measure the diameter of the shoes then the diameter of you hub to make the right adjustments but we didn't have it so just do trial and error....the rotor is sopposed to fit over the shows snuggly!



Clean these up again

Put on the caliper with the 16mm's

Compress that piston

Pads in Ready for the allen bolts

Hand tighten then wrench tighten

Spring on the outside and your done

Now the Passenger Side Rear has a sensor. (this sensor was not worn down so we put it back in there...it has a lil clip that keeps it in place.

5speedsteve 10-13-2006 10:17 AM


So lets make this clear there are 2 sensors Front Driver and Rear Passenger.

Now i was thinkin about doing a DIY: wheel aligment.. :idea: :excited: :hmm: but being how the machine and aligment rack cost well over $25,000 its not really a diy job :shhh:

You start by torquing all your wheels to 80ftlbs. and i put 36psi in the rear and 32 psi in the front

Then on go the sensors

and the rest is history



purin 10-13-2006 08:49 PM

i was thinking about getting rotors off a friend and doing this for the fronts. besides the rotors, there aren't any other required parts like bolts except the tools correct? just like changing out brakes pads? I'm not sure what the sprints you mention are for? Will I see it when i remove the calipers? I think i will give this a try. at least remove and reassemble ^^
thanks for the write up.

5speedsteve 10-13-2006 09:06 PM

there one spring on the outside of each caliper, its just this 5 inch long metal thing that keeps the out brake pad snug, ull see it

i wouldn't recommend putting on news rotors and keeping your old pads....there bound to sqweek....and if the rotors are used i would get them refinished so they have a flat surface to start with

Custom3 10-13-2006 09:13 PM

damn man nice diy...thanks for sharing

purin 10-13-2006 11:36 PM

the rotors are used but like less than a month and plus his pads that he got at the same time. do you think it will be ok?

5speedsteve 10-14-2006 10:43 AM

if you keep the same pads on the same rotors you should fine

thumper 12-02-2006 03:55 PM

thanks for the great write-up.

Mteknic330ci 03-27-2008 12:22 PM

Dont forget to pull the cap off the brake fluid housing before you compress the pistons or you will get air bubbles in the line...

aggieE46 03-27-2008 04:25 PM

Dude, you're two years too late!


Originally Posted by Mteknic330ci (Post 7635777)
Dont forget to pull the cap off the brake fluid housing before you compress the pistons or you will get air bubbles in the line...

JamesH325Ci 03-27-2008 04:35 PM


Originally Posted by aggieE46 (Post 7637326)
Dude, you're two years too late!


Kmoy2002 03-27-2008 08:14 PM

Good one.

dirsh 03-27-2008 10:37 PM

never seen this DIY before.

EXCELLENT write up. I need to do mine asap. I haven't done a brake job in years so it was a good refresher


Mteknic330ci 03-28-2008 11:32 AM


Originally Posted by aggieE46 (Post 7637326)
Dude, you're two years too late!

lol obv, im just noteing for future use of this thread....

5speedsteve 03-29-2008 03:41 AM

wow i miss my car

sapiro 04-13-2008 01:26 AM

excellent write-up. PROPS!!!

jmctype4 04-13-2008 02:54 AM

1 Attachment(s)

Originally Posted by 5speedsteve (Post 4998108)

Two words, boys and girls: USE PROTECTION

Awesome writeup - complements the diy at madrussian.net.


John_Peters 04-14-2008 09:06 AM


Originally Posted by jmctype4 (Post 7734641)
Two words, boys and girls: USE PROTECTION

Awesome writeup - complements the diy at madrussian.net.


I have to second this notion. I just did this on saturday, and when I finished my hands looked like I worked in a coal mine.

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