Brake discs & pads swap
I have to change the front and rear brake discs and pads on my 2005 Proton Gen 2 1.6 manual. At present I don’t have a workshop manual for the car and need some advice on the procedure involved. For the rear discs, will I need a wind-back tool for the calipers and will the handbrake need resetting once the new parts are fitted? Do you have any information on the hub nut torque settings and what not to do if I am to avoid damaging the ABS? Gary Coles
The front brake pads are quite straightforward and the pistons should push back easily with a large pair of grips. Push the piston in slowly and ensure there is sufficient space left in the brake reservoir to enable the fluid to flow back into the reservoir. If there is not sufficient space, you should either syphon out some fluid or put some rags around the cap to soak up the excess fluid. When disposing of the cloth, remember that brake fluid is corrosive and will damage paintwork.
The hub nuts should not need to be disturbed to replace either the front or rear brake discs. The discs are held in place on the hub by a small fixing screw. Likewise, as the hubs do not need to be removed, you should not be in any danger of disturbing or damaging the ABS sensors.
The discs may be corroded onto the hubs and may need tapping to free them off. When fitting the new discs, ensure the hub is free from rust and debris; using a wire brush to clean away any deposits is recommended.
When replacing the rear brake pads, first ensure that the handbrake levers are fully back against the stop. If they are not, then slacken off the handbrake cable. If they still do not go back fully to the stop, it could be that the lever mechanism has seized and may either need freeing off or the caliper may need replacing.
According to the data I have, both rear pistons wind back on a clockwise thread. A universal wind-back tool should do the job or you may be able to wind them back using a pair of long-nose pliers, locating the tips in the small slots in the piston and winding in while pushing.
Once the new brake pads are in place and the caliper refitted, confirm that the handbrake levers on the calipers are fully back against the stops, then pump up the brake pedal to set the brake pads into position. After the brake pedal has been pumped up, test the handbrake to ensure it is operating correctly.