First off let me say that this thread is not meant to bash anyone or anything, it is meant purely as a reference. Seeing as I do not own every single E46 ever made I cannot 100% guarantee a single solution will work for you, the best I can do is cross reference part numbers. Please avoid filling this thread with questions like "Why would you want to do _ when you can do _?" as well as any other non related topics. If you notice an error please let me know so I can correct it. I will not be making specific pad, rotor, or fluid recommendations because everyone uses their car differently. Track pads are probably not ideal for someone who dailies their car, and some people prefer one style of rotor to another. I will do my best to include links where applicable. The last thing I have to say is PLEASE BUY QUALITY PARTS. Yes, eBay rotors and pads may get you down the road but it's your life, your car, and your money. Let's get started!
For Non-M Cars Only!
Stage 1 - For All Cars
Stage 2: 330i/ci/xi Upgrade - For 323/325/328 Cars
17" Wheels required. Front rotor size: 325mmx25mm. Rear rotor size: 320mmx22mm.
This process is the same as a standard brake service, however instead of putting your old parts on you replace them with parts from a 330i/ci/xi.
Stage 2.5: M3 Upgrade - For All Non-M Cars
17" Wheels (M3 Rotors) -18" Wheels (CSL Rotors) required. Front rotor size: 325mmx28mm (M3) - 345x28mm (CSL). Rear rotor size:327x20mm.
This process is similar to the 330 upgrade, but requires some machining.
Stage 3: Porsche 996 Upgrade - For All Non-M Cars
17" Wheels (M3 Rotors) -18" Wheels (CSL Rotors) required with +35mm offset or lower. Front rotor size: 325mmx28mm (M3) - 345x28mm (CSL). Rear rotor size:327x20mm.
This process is similar to the 330 upgrade, but requires some grinding/machining and minor wiring. The wear sensor wires must be spliced between the 996 sensor (pad side) and the E46 sensor (vehicle side).
Stage 4: 135i Upgrade - For All Non-M Cars
17" Wheels required with +35mm offset or lower. Front rotor size: 325mmx25mm (unless using ECS kit or custom brackets). Rear rotor size:327x20mm.
This process is similar to the 330 upgrade, but requires some cutting and minor wiring. The wear sensor wires must be spliced between the 135i sensor (pad side) and the E46 sensor (vehicle side).
I will update this thread as I find time. I hope this is a good start for some of you, and I hope it's good enough to not be deleted right away. Every other forum I've been on has had guides like this posted, but I have not found very many on this forum. PLEASE SEND OR POST PICTURES OF YOUR BRAKES!!!
For Non-M Cars Only!
Stage 1 - For All Cars
- New pads and rotors meant for how you drive your car (street, track, autocross, etc...).
- Flush the system with DOT 4 or higher fluid.
- Replace rotor screws anytime you remove old ones. They're so cheap it's not worth the hassle of having old, stripped screws.
- Replace wear sensor. Not needed every time you touch the brakes, but it is a good thing to consider depending on the age and mileage of your sensor.
- (Optional) Stainless Steel Brake Lines. Not needed, but will give you a slightly improved pedal feel.
- (Optional) Speed Bleeders. Not needed, but allows the brakes to be bled quickly and you don't need a second person do do them. Worth every penny - http://www.speedbleeder.com/
Stage 2: 330i/ci/xi Upgrade - For 323/325/328 Cars
17" Wheels required. Front rotor size: 325mmx25mm. Rear rotor size: 320mmx22mm.
This process is the same as a standard brake service, however instead of putting your old parts on you replace them with parts from a 330i/ci/xi.
- 330 Calipers
- 330 Caliper Carriers
- 330 Pads
- 330 Rotors
- 325xi/330/M3 Wear Sensor - The part number is different between the 325i/ci and the 330. The part number is the same between the 325xi and the 330. I cannot confirm if it is indeed different, but again it is good to replace anyways.
- Flush the system with DOT 4 or higher fluid
- 325/330 Rotor Screws
- (Optional) When doing the rear, you will lose the parking brake functionality unless you swap the rear trailing arms and hub assembly from a 330 because the parking brake shoes are larger. With a 325xi you already have the larger 330 sized parking brake so this does not apply to you.
- 330 Stainless Steel Brake Lines. Not needed, but will give you a slightly improved pedal feel.
- (Optional) 330 Speed Bleeders. Not needed, but allows the brakes to be bled quickly and you don't need a second person do do them. Worth every penny - http://www.speedbleeder.com/
Stage 2.5: M3 Upgrade - For All Non-M Cars
17" Wheels (M3 Rotors) -18" Wheels (CSL Rotors) required. Front rotor size: 325mmx28mm (M3) - 345x28mm (CSL). Rear rotor size:327x20mm.
This process is similar to the 330 upgrade, but requires some machining.
- M3 Calipers
- M3 Caliper Carriers - SPINDLE MOUNTING TABS MUST BE MACHINED 6.35mm
- M3 Pads
- M3 Rotors
- 325xi/330/M3 Wear Sensor
- Flush the system with DOT 4 or higher fluid
- M3 Rotor Screws
- (Optional) When doing the rear, you may have to swap the entire rear subframe/differential assembly from an M3. You may only need the 330 trailing arms and hub assembly because the 330 and the M3 share the same parking brake, but there is no solid information about this available.
- M3 Stainless Steel Brake Lines. Not needed, but will give you a slightly improved pedal feel.
- (Optional) M3 Speed Bleeders. Not needed, but allows the brakes to be bled quickly and you don't need a second person do do them. Worth every penny - http://www.speedbleeder.com/
Stage 3: Porsche 996 Upgrade - For All Non-M Cars
17" Wheels (M3 Rotors) -18" Wheels (CSL Rotors) required with +35mm offset or lower. Front rotor size: 325mmx28mm (M3) - 345x28mm (CSL). Rear rotor size:327x20mm.
This process is similar to the 330 upgrade, but requires some grinding/machining and minor wiring. The wear sensor wires must be spliced between the 996 sensor (pad side) and the E46 sensor (vehicle side).
- Porsche 996 Front Calipers (PN 996.351.425, 996.351.426) - Machine mounting bosses 12mm for use with M3 rotors, do not machine for use with CSL rotors
- RallyRoad Front Caliper Brackets - Rally Road | RallyRoad.net
- Porsche 996 Rear Calipers (PN 996.352.421 996.352.422)
- RallyRoad Rear Caliper Brackets - Rally Road | RallyRoad.net
- Porsche 996 Pads
- Porsche 996 Pad Shims - These prevent the brakes from squaking like many people complain about. Not needed, but cheap enough to not skip over.
- RallyRoad Front Brake Lines - Rally Road | RallyRoad.net
- RallyRoad Rear Brake Lines - Rally Road | RallyRoad.net
- M3/CSL Rotors - Read above
- 325xi/330/M3 Wear Sensor
- 996 Wear Sensor
- Flush the system with DOT 4 or higher fluid
- M3 Rotor Screws
- Grind casting marks on the spindle - This will vary between vehicles. On some (most?) you will need to grind away the casting lines on the spindle so that the caliper bracket sits flush. It is nothing major, but it does need to be noted.
- (Optional) When doing the rear, you will lose the parking brake functionality unless you swap the rear trailing arms and hub assembly from a 330 because the parking brake shoes are larger. With a 325xi you already have the larger 330 sized parking brake so this does not apply to you.
- (Optional) 996 Speed Bleeders. Not needed, but allows the brakes to be bled quickly and you don't need a second person do do them. Worth every penny - http://www.speedbleeder.com/
Stage 4: 135i Upgrade - For All Non-M Cars
17" Wheels required with +35mm offset or lower. Front rotor size: 325mmx25mm (unless using ECS kit or custom brackets). Rear rotor size:327x20mm.
This process is similar to the 330 upgrade, but requires some cutting and minor wiring. The wear sensor wires must be spliced between the 135i sensor (pad side) and the E46 sensor (vehicle side).
- 135i Calipers
- 135i Caliper Brackets. Stock caliper brackets will leave a little bit of pad overhang. Not 100% ideal, but will work fine. Currently the only solution is to buy the whole kit from ECS tuning or have custom brackets made.
- 135i Pads
- (Unsure) Extended Front 135i Brake Lines - Stock 135i lines MAY work. Not sure on where to get these other than having a set custom made, need to be 600mm long. Front 135i lines can be used on the rear to possibly solve the rear length issue if needed.
- 330 Front Rotors
- M3 Rear Rotors
- 325xi/330/M3 Wear Sensor
- 135i Wear Sensor
- Flush the system with DOT 4 or higher fluid
- 330 Rotor Screws
- M3 Rotor Screws
- Trim/replace rear dust shield - In order to clear the M3 rotor on the dust shield must be trimmed or replaced with an M3 shield.
- (Optional) When doing the rear, you will lose the parking brake functionality unless you swap the rear trailing arms and hub assembly from a 330 because the parking brake shoes are larger. With a 325xi you already have the larger 330 sized parking brake so this does not apply to you.
- (Optional) 135i Speed Bleeders. Not needed, but allows the brakes to be bled quickly and you don't need a second person do do them. Worth every penny - http://www.speedbleeder.com/
- (Optional) The stock 135i caliper pistons are prone to cracking under hard (read:track day bro) use. Replace with a quality set of pistons.
I will update this thread as I find time. I hope this is a good start for some of you, and I hope it's good enough to not be deleted right away. Every other forum I've been on has had guides like this posted, but I have not found very many on this forum. PLEASE SEND OR POST PICTURES OF YOUR BRAKES!!!