HOW TO: Replace/Upgrade rear rotors (and some extras)

[DaveHAT]

Well ... seeing as 2007 has unofficially been dubbed the "year of the brake upgrade" :) it was decided at the Team Pumpkin AGM last week that we could not have our opening battsman Mr SSUte01 running 115+ mp/h passes on stock brakes. So some phone calls were made and a package to address this travesty was composed. The following write up is aimed at the how to section of replacing/upgrading of the rear rotors on a VT onwards Commodore plus we've added some extra special pics for bling value.

Step one ... as always is raise the car using jacks and secure utilising car stands or similar.

Step 1.5: Remove the wheels from the car (thanks Matt :) )

Step 1.75 RELEASE THE HANDBRAKE !!!!! (Thanks K) :werd:

Step 2:Remove the 2 x 19mm Caliper bolts and hence the caliper:
http://www.trackchat.com.au/media/data/500/medium/Rear_caliper.JPG

Once you have removed these 2 bolts the caliper will slide off the rotor.

Step 3: Remove the rear rotors:
The rear rotors come off Uber easily as seen here:http://trackchat.com.au/media/data/500/Removing_rear_caliper_movie.MPG

Grab it and give it a gentle wriggle and it should come free. Some GENTLE encouragement may be applied with a rubber mallet but for the love of SMURFS ... DON'T BELT IT WITH A HAMMER TO GET IT OFF !!!! Seeing the handbrake shoes go flying across the yard is most un-excitifying. :confused:

Step 4: The rotor is removed and now for the cleaning of the hubs and stubs:
http://www.trackchat.com.au/media/data/500/medium/Rear_caliper_removed.JPG

Step 5: Get a beer and admire you achievements ... :lol: Yes I said beer not VB :D

Reassembly is just the reverse of the above steps. Once the hub and studs are clean, place the new rotor onto the stubs/hub and push it over the handbrake shoes until it sits nicely. We used some of RBS Matts new molycarbinate beauties on Luke's ute and they are an impressive looking bit of kit. We also slapped some go fast red paint onto to the calipers to give them a bit of a tart up and to match the new front rotors/calipers.

[DaveHAT]

PartII: FRONT ROTOR/CALIPER UPGRADE TPR STYLE...

Not to be outdone by the Eastern Suburbs performance centre we also installed some 330mm x 32mm front rotors to the Punky rocket.

As per Duncan's HOW TO: 330mm AP Racing brakes thread we followed much the same process installing the 330mm rotors and calipers to the ute. We have included some extra photo's of the removal of the OEM dust shield to allow the fitment of larger rotors. Removing the front dust shield is a MUST DO if you want to fit larger than OEM rotors.

With the front rotors/calipers removed you should be left with this:
http://www.trackchat.com.au/media/data/500/medium/Front_caliper_removed.JPG

THUS: You need to drill out the 3 rivets that secure the shield to the hub:
http://www.trackchat.com.au/media/data/500/medium/Front_caliper_rivet.JPG
http://www.trackchat.com.au/media/data/500/medium/Front_caliper_rivet_drilled.JPG

Once you've drilled the 3 rivets out you will need to cut the shield off using tin snips or similar:
http://www.trackchat.com.au/media/data/500/medium/Removing_dust_sheild.JPG

Leaving you with this:
http://www.trackchat.com.au/media/data/500/medium/Front_rotor_and_shield_removed.JPG

You're now ready to fit the new rotors/calipers/pads ala this:
http://www.trackchat.com.au/media/data/500/medium/Front_caliper_pad_insertion.JPG
http://www.trackchat.com.au/media/data/500/medium/front_caliper_new.JPG

For comparison:
http://www.trackchat.com.au/media/data/500/medium/front_caliper_old.JPG

All bolted back together and ready for some bedding in.:
REARS
http://www.trackchat.com.au/media/data/500/medium/Rear_rotor_completed.JPG

FRONTS:
http://www.trackchat.com.au/media/data/500/medium/Front_rotors_completed.JPG

It took us about 3hrs to complete the brake upgrade with good results.

Special thanks need to be given to:

NickS for hardware support
RBSMatt: For the Tippy top molycarbide rear rotors.
Stopmaster brakes Newcastle for the front rotors.
Ebay for the ongoing acquisition of parts that get added to the stockpile.
Medowie speedshop for opening on a Sunday to let us have a play ...

[DaveHAT]

ADDIT:

We realise that there are some holes in the HOW TO side of things but you sort of get caught up in the doing side of things and forget to take pictures.

We hope that this will be of some use to anyone contemplating performing their own brake upgrades, and that in combination with Troy's front brake install and Dunc/Erik's 330mm upgrade the total of the info and pics will be of some assistance. :beer:

EDIT AND A MAJOR ONE AT THAT ... :lmao: INDEED Mr K, the most vital ingredient in the removal of the rear rotors is ...
MAKE SURE THE HANDBRAKE IS OFF BEFORE STARTING ... :lol: :bravo:

[lautray]

A little tip: don't forget to release the handbrake or you'll have the oxy out trying to remove rear rotor :headbang: . Not personal experience, but have heard stories to that effect :lol:.

[SSUte01]

Very big thanks to Dave for all the work and support and after a short drive (~60km) the pedal feel is back to where it was before, if not better and the stoppers work as well as they look.

All in all a vey worthwhile mod with plenty of practicality as well as 'some' wank factor to boot but I am one very happy camper.

P.S - Medowie Speedshop's panel beater did a grouse job repairing my somewhat annoying front bumper, good as new :p

[Y2kGoofball]

Step 1.5

REMOVE THE WHEEL FIRST!!!

It'll make accessing the calliper and disc a hell of alot easier :stick:

Also on topic there is a Handbrake Modification kit out for the shoes - I got told $30 to me (dunno the RRP but it wouldnt be much more) which I am going to get for my VX at its next service.

Basically its a modified spring of some description which stops the shoosh shoosh shoosh shoosh noise all Commodores and Monaros seem to have by pulling the shoes off the disc. It also stops one side from clunkining when the handbrakes pulled - if you tried to pull your handbrake on at low speed one side will suddenly grab and dip down quite violently. apparantly this stops the dip.

One of the boys at work is an ex Holden head technician so hes going to install it for me - I'll keep you guys updated but if your going to be doing anything with the rear brakes it sounds like this mod might also come in handy.

[35R]

well done guys.

any judgement on the moly-carbide rears yet?

[NickS]

Top work team Pumpkin ... :bravo: ... :thumbs: ... :bow:

[seedyrom]

Also on topic there is a Handbrake Modification kit out for the shoes - I got told $30 to me (dunno the RRP but it wouldnt be much more) which I am going to get for my VX at its next service.

Basically its a modified spring of some description which stops the shoosh shoosh shoosh shoosh noise all Commodores and Monaros seem to have by pulling the shoes off the disc.
VERY interesting in this. Please keep posted.
Does anyone else know about this?

[NickS]

Basically its a modified spring of some description which stops the shoosh shoosh shoosh shoosh noise all Commodores and Monaros seem to have by pulling the shoes off the disc.

What's this noise, when do you hear it ... I have had lots of Commodores / HSVs and have never had any shoosh shoosh shoosh noise ???

:confused:

[seedyrom]

a slow 5-10km/h drive in a car park or next to a concrete barrier is enough to make my car sound like a taxi with a billion k's on it

[seedyrom]

oh, and nice write up Dave :)


Now is it just me that has trouble accessing the bottom caliper bolt when removing the rears?

I find I need to use a scissor jack to raise the strut and assembly a couple of inches to get my socket onto the caliper bolt (I dont have a 19mm ring spanner).

Maybe I should just get a 19mm ring spanner and be done with it

[BOMI]

Good write up fellas :thumbs: Will be interesting to see how the MC Rotors go.

Also Y2KGB, Im interested in the hand brake info, keep us posted!

Nick the SS does the swoosh swoosh, very crapy sound, very taxi like :lmao:

Troy :)

[seedyrom]

http://www.trackchat.com.au/media/data/500/medium/Removing_dust_sheild.JPG

I love that shot. Should have hit those tin snips with the WD-40 and wire brush while you were there :D

[DaveHAT]

I love that shot. Should have hit those tin snips with the WD-40 and wire brush while you were there :D

It's taken 25 years for them to get to that condition, my grandpappy was very proud of his wee tin snips. I'm afraid if I remove the rust from them they'll fall apart. :D

Re: feedback on molycarbinate rotors ... none as yet, focus yesterday was on getting pedal pressure up to pre change position. They seem to stop thus far which is a good thing.

Fair bit of smoke coming from them but purely due to oil coating and over spray of paint onto the rotor face. The panel beating/spary painting dept of Medowie speedshop is not known for its accuracy with the spray tin. :werd:

[Ron]

Well done again Dave at the Medowie speed shop :bow: it provides everything ,mobile workshop, tuning, brake and suspension upgrades even furniture removalist :werd: :confused:

[mad_HAT]

What's this noise, when do you hear it ... I have had lots of Commodores / HSVs and have never had any shoosh shoosh shoosh noise ???

:confused:


I too have the woosh woosh - can be heard at low speeds when driving past something that can bounce the noise back.

Thanks goof, till now I dodnt know what it was.:confused:

[NickS]

Well done again Dave at the Medowie speed shop :bow: it provides everything ,mobile workshop, tuning, brake and suspension upgrades even furniture removalist :werd: :confused:

Ahhh yes ... the little known and seldom used removalist division ... apparently they build a mean gazebo too, MAGICAL !!! ... :shock:

This swoosh swoosh noise is interesting, I've never heard it !!! :confused:

[DaveHAT]

Re: the swoosh swoosh noise of the handbrake dragging on the inside of the rotor, the other (free) option is to just remove the rear rotors as shown above and give the adjusting spring and internals of the rear handbrake/rotors a good spray with some monkey piss. :yep:

Something like WD40 or similar would do and give the whole lot a good clean with a wire brush or a blast with some compressed air for those who may have access to a compressor.

My SS was doing this very thing & that's what I did & it hasn't done it again :thumbs:

A gazebo ... :confused: how did that get in here ??

[Y2kGoofball]

Dave, thats a good suggestion too!!!

Seeing as Ive got access to a former head holden tech I'll let him show me how to install the 30 buck kit and let you guys know, Im not back at work for 2 weeks so it wont be anytime real soon.

Nick the swoosh swoosh swoosh or whoosh or however to describe it, as mentioned, can be heard wherever noise bounces off a wall at low speed.

I find I hear it with the window down as I travel through the M4 tolls of an afternoon, max speed about 45kph if Im lucky.

Its not just Commodores though, if you listen to most Falcons as they drive past you anywhere up to 45ish Kph you'll hear it too. I noticed it when I was having a coffee and a few Falcons drove past at a slow speed. I also could hear it coming from a Falcon to my right when I had the window down one day and we were doing about 50kph on a 2 laned street.

[Pulse Red]

I have heard Magna's making the same woosh, woosh noise to.

[Y2kGoofball]

I think they use the same handbrake setup concept, although I havent ever looked at the handbrake setup of a Falcon or Magna or Camry etc

[Febs]

Great write-up as always Dave. :werd:

Basically its a modified spring of some description which stops the shoosh shoosh shoosh shoosh noise all Commodores and Monaros seem to have by pulling the shoes off the disc. It also stops one side from clunkining when the handbrakes pulled - if you tried to pull your handbrake on at low speed one side will suddenly grab and dip down quite violently. apparantly this stops the dip.

VERY interested in this! Please keep us posted!
I heard the shoosh shoosh was something to do with the handbrake being too tight or something, but surely it must be something more complex than that. This kit sounds good for $30, if it does what it claims. :)

What's this noise, when do you hear it ... I have had lots of Commodores / HSVs and have never had any shoosh shoosh shoosh noise ???

:confused: :confused: :confused:
You must be one of the lucky ones then! Almost every VT-VZ, and AU+ Falcon I've ever seen has this noise at low-speeds. That's a heckofalotta cars!

Cheers,
- Febs.

[BOMI]

Nick would never hear this noise as his windows are always up, AC on, vivaldie cranking :stick: :stick: :lmao:


Troy :)

[NickS]

Nick would never hear this noise as his windows are always up, AC on, vivaldie cranking :stick: :stick: :lmao:


Troy :)

Ohh yeah ... that's probably it :yep:

Honestly I have never ever heard this noise, I made a conscious effort to listen this morning ... nothing. Lucky me I guess ... :D

[seedyrom]

or is it cause Nick always upgrades his brakes?

I can confirm that Falcon BA's, BF-I's and BF-II's do it too (in pov pack [XT] trim anyway).

As febs said, a heck of a lot of cars.

Who is the company making such a killing from the local car companies by supplying bodgy goods, with no subsequent R&D to improve the product. Must be a very cheap part

[Febs]

or is it cause Nick always upgrades his brakes?

Mine still does it with the PBR PK1 kit...though not as badly as it used to.

Cheers,
- Febs.

[seedyrom]

http://www.fordforums.com/showthread.php?p=1130906

Yup, Blue Camp complaining too - interesting to see what the Technician said.

So your $30+ option ... is it a solution? or just new shoes ?

[235rwkw]

i noticed you use those new light hard rear rotors

how are they ?

[Y2kGoofball]

Seedy, I am yet to acctually see the kit but Im told its a "kit" aka solution - definately not new shoes.

I asked one of our mechanics, who up until this time last year was a head tech at Holden, if he could do a 110 000 k service on the VX.

We then took my car last week to grab some lunch and he said "oh when you ask them for the service bits ask them for the anti scrape kit". I'm thinking??

"surely youve heard the shoosh shoosh from the rear end?" he asked. Obvious response - "yes"
"Yeh well theres a modified kit that includes springs and all sorts of things for the handbrake shoes. It pulls the shoes off the disc coz thats whats creating the noise, and it also makes handbrake activation smoother. You wouldve noticed one side dips down violently when you pull the handbrake up, this makes both sides come on evenly and smoothly.

Ive fitted them to many cars, will only take me a few minutes to do while the wheels off".

I rang parts to get an idea on price, and said "oh and something about a hand brake anti shoosh kit?". He knew about it and says "hang on ... ... ... yep anti scrape kit, $30 to you Ive got one here. I dont know how to fit it, looks like it needs drilling or something but Ive sold a few so it must be good"

When im back at work in 2 weeks time I'll get the bits in and have a looksy and see how its done. The mechanic seems confident tho that its only a few minute job and it works, but I'm just repeating what Ive been told, I havent acctually seen the kit yet.

Once its installed and if it works, I'l post the part number and fitting instuctions so everyone knows, because if I hadnt spoken to this mechanic I wouldnt've known either.

[SSUte01]

i noticed you use those new light hard rear rotors

how are they ?

Moly Carbide I think is what they are called. To be honest I don't know a great deal about them perhaps RBS Matt or one of the other brake gurus can comment. They seem fine although I do not drive my car that often so I have only been about 70km since they were put in. I cannot give any real tangible feedback other than at this early stage it feels every bit as good as before and it is getting better each time I drive it.

For me I opted for std size rear for two reasons a)cost and b)drag radials fit over without any fuss.

Seems spot on thus far - touch wood

Luke:)

[seedyrom]

Rather than take Dave's thread any further off track, here's a new thread to discuss the Handbrake service fix kit.

http://www.trackchat.com.au/forum/showthread.php?p=6852

(Instead of waiting for the goofball :stick: I thought I'd just go in and ask Holden whether they knew anything about it)

[DaveHAT]

i noticed you use those new light hard rear rotors

how are they ?

Round and shiney and they stop ... that's about the only evaluation able to be provided in the 3 days since fitting. :yep: we both fitted them.

From the aesthetic P.O.V I think they're great, they look the goods and that must be worth 20 tenths depending on who you ask... and the barometric pressure of course :D :yahoo:

Sorry Steve, I didn't recognise you without your 4000 posts :lol:

Nick would never hear this noise as his windows are always up, AC on, vivaldie cranking :stick: :stick: :lmao:
Troy

Vivaldie ... ! :confused: ...

Atell ---> definitely ... Accounting 101 ---> Maybe ... Vivaldie ---> :nopity: :mgun:

[Y2kGoofball]

sorry for hi jacking your thread Dave, I'll shut up now :eyes:

[DaveHAT]

sorry for hi jacking your thread Dave, I'll shut up now :eyes:

No problems Matt, it was useful information relevant to the topic in question ...

Now ... no more destabilising of the trackchat forum with off topic posts please Matt ... it's disruptive and could end in a ban .... :lol::lmao::waving:

:D KIDDING ! :D




Now where did I leave my hat ... :confused: ?





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