How To: 8G Rear Disc Brake Conversion
I made a tutorial a few years ago on how to convert the rear drum brakes to rear disc brakes.
Here's the link on GalantForums.com (for those registered there as well)
http://www.galantforums.com/phpbb/vi...hp?f=91&t=2656
full tutorial:
Ok, so i finally changed my rear drums to disc brakes. Special thanks to 90crxfreak for helping me with the install, rez888 for having the brakes for sale, and all the members of GalantForums.com who gave me info on the brakes. Now, onto the tutorial.....
The brakes were from a '99 Galant V6, didn't take a pic of them before hand, but they were a lil rusty and the backing plates were bent out of shape, so we fixed them up and a local shop resurfaced the rotors. You'll need PB Blaster, a 10mm and 12mm wrench, vice grip wrench, torque wrench, pry bar (if necessary), breaker bar, 14mm wrench or socket (preferably socket), screwdriver, flashlight (if in night), some good food and good music! :D
First up, block the front wheels with bricks or anything that will prevent the car from rolling, jack up the car and remove the wheels, and disengage the E-Brake. (And use jack stands to keep car up.)
Next , remove the drum....refer to the service manual in the "Downloads" section to see the complete drum assembly.
(http://www.galantforums.com/modules.php?name=Downloads)
Here's some pics with the drum off the car....
http://i165.photobucket.com/albums/u...ovalMedium.jpg
Notice the small hole next to one of the large lug nut holes, there's two of these holes that are threaded for a 12 mm bolt which will remove the drum off the hub.
http://i165.photobucket.com/albums/u...movedrumMe.jpg
(Note: tighten the two bolts evenly to remove the drum.)
http://i165.photobucket.com/albums/u...drumMedium.jpg
Okay, now the assembly should look like this...
http://i165.photobucket.com/albums/u...mblyMedium.jpg
Next, unscrew the hard line from the soft line from the drum asembly. PPreferably, use a 10mm line wrench, but if you don't have a line wrench, use vice grip wrenchs, and be aware to not tighten so tight that it distort the 10mm fitting. Use PB Blaster to loosen the 10mm fitting.) (this pic does show the disc, but is used at this time to show use of the vice grips.)
http://i165.photobucket.com/albums/u...lineMedium.jpg
Next, remove the soft line C clip that is holding up the soft line. As soon as you do this, the soft line can be seperated.
http://i165.photobucket.com/albums/u...lineMedium.jpg
(Note: wiggle the clip back and forth for easy removal.)
http://i165.photobucket.com/albums/u...lip2Medium.jpg
Next, remove the 12mm bracket for the soft line that is attached to the knuckle, use PB Blaster.
http://i165.photobucket.com/albums/u...rumsMedium.jpg
Next, remove the four bolts in the back of the knuckle that runs through the backing plate and the hub.
http://i165.photobucket.com/albums/u...oltsMedium.jpg
http://i165.photobucket.com/albums/u...oltsMedium.jpg
(This pic will be used later, it's just a refernce to where the bolts are :wink: . Use PB Blaster in the back, in the bolts, and where the hub is located.)
Next, remove the hub and the backing plate.
Note: Some excessive force may be necessary....(90crxfreak aka Jared takin a crack at it :lol: )
http://i165.photobucket.com/albums/u...ingplateof.jpg
Now, the "bare" knuckle should look like this...
http://i165.photobucket.com/albums/u...ckleMedium.jpg
Now, in order to get the complete drum brake assembly off, you need to detach the E-Brake cable. To do this, you first must remove the C clip from the inside of the backing plate.
http://i165.photobucket.com/albums/u...lateMedium.jpg
(Disregard the focused hub, my photography is terrible :oops: 8O )
Note: Wiggle the C clip to one side where you can get the screwdriver in between the C clip and the E-Brake cable. Pry off from the E-Brake cable.
http://i165.photobucket.com/albums/u...late2Mediu.jpg
http://i165.photobucket.com/albums/u...late3Mediu.jpg
Now, take a screwdriver and push the E-Brake mechanism inward towards the other side, like so....
http://i165.photobucket.com/albums/u...everMedium.jpg
Now you can access the actual cable connected to the mechanism you pulled up. Might be a lil difficult, but take off the cable from the mechanism.
http://i165.photobucket.com/albums/u...ovedMedium.jpg
Now that the E-Brake cable is out, just remove it from the drum assembly.
Front
http://i165.photobucket.com/albums/u...rontMedium.jpg
and side image
http://i165.photobucket.com/albums/u...sideMedium.jpg
ok, flip the disc backing plate to the back, you'll notice the piping for the E-Brake is too small and too long for the E-Brake to fit.
http://i165.photobucket.com/albums/u...iscsMedium.jpg
http://i165.photobucket.com/albums/u...tubeMedium.jpg
So, we have to drill the hole wider and use the dremel to cut the top down about 2mm.
http://i165.photobucket.com/albums/u...pipeMedium.jpg
http://i165.photobucket.com/albums/u...dlolMedium.jpg
http://i165.photobucket.com/albums/u...pipeMedium.jpg
http://i165.photobucket.com/albums/u...slotMedium.jpg
and here's what it looks like after drilling and dremeling...
http://i165.photobucket.com/albums/u...lingMedium.jpg
our calculations aren't exact, so measure how far you have to cut, so take your time with the customization.
Now, you have to grind down the C clip opening on the cable itself, be EXTRA careful when doing this, it shouldn't be much more bigger than the dremel cutting disc itself.
http://i165.photobucket.com/albums/u...ningMedium.jpg
Now, test fit and make sure that the cable fits in perfectly with the E-Brake cable C clip.
Then take the cable out after the test. To secure the brake cable, drill a hole on the side of the backing plate shown here...
http://i165.photobucket.com/albums/u...holeMedium.jpg
Now, put the E-Brake cable back into the piping and attach the cable into the center-moving mechanism(parking brake lever).
http://i165.photobucket.com/albums/u...rcableMedi.jpg
the backing plate bolt will help you to get the E-Brake cable into the parking brake lever
http://i165.photobucket.com/albums/u...ableMedium.jpg
Install the Brake disc C clip after putting the whole assembly back on the knuckle (connect hub to backing plate, then both to the knuckle. make sure the hub is in the correct position, the 4 bolt holes should align perfectly.)
http://i165.photobucket.com/albums/u...ghubMedium.jpg
http://i165.photobucket.com/albums/u...hub2Medium.jpg
http://i165.photobucket.com/albums/u...lip2Medium.jpg
http://i165.photobucket.com/albums/u...clipMedium.jpg
Now, with the hole you drilled on the side of the backing plate, tie the cable taut with the backing plate using a ziptie.
http://i165.photobucket.com/albums/u...tmfwMedium.jpg
http://i165.photobucket.com/albums/u...ziptieMedi.jpg
Make sure you clean the assembly real good, use brake cleaner...
http://i165.photobucket.com/albums/u...anerMedium.jpg
Get those rotors too...and wipe off the dirt on the rotors too
http://i165.photobucket.com/albums/u...aner2Mediu.jpg
http://i165.photobucket.com/albums/u...leanerMedi.jpg
when putting the backing plate back on the knuckle, use a torque wrench and tighten to 60ft/lbs. No more, no less...
http://i165.photobucket.com/albums/u...nch60ftlbs.jpg
Now, install the rotor
Make sure the piston on the caliper is fully in, has to be done evenly, and be careful, cuz you can tear the inner piston ring, which may require a complete caliper overhaul, once again, take your time.
http://i165.photobucket.com/albums/u...persMedium.jpg
http://i165.photobucket.com/albums/u...ers2Medium.jpg
Now, remove the old hard lines from the calipers, use PB Blaster
http://i165.photobucket.com/albums/u...lipersoftl.jpg
For those who don't know what PB Blaster is...
http://i165.photobucket.com/albums/u...sterMedium.jpg
Now, install the brake pads into the calipers, then install the soft brake line. Make sure you put in the C clip before you attach the hardline, this will make it easier to tighten.
use Brake Quiet (or brake silencing grease, usually sold with new pads at local auto store)
http://i165.photobucket.com/albums/u...epadsMediu.jpg
pads into the caliper(this is me run1206 :orangesmile: )...
http://i165.photobucket.com/albums/u...liperMediu.jpg
caliper onto the backing plate
http://i165.photobucket.com/albums/u...persMedium.jpg
install C clip...
http://i165.photobucket.com/albums/u...lineMedium.jpg
http://i165.photobucket.com/albums/u...ine2Medium.jpg
screw bolt tight with vice grips (don't over-tighten)
http://i165.photobucket.com/albums/u...lineMedium.jpg
http://i165.photobucket.com/albums/u...lineMedium.jpg
don't forget to spray the bleeding screw with PB Blaster (to prevent stripping)
http://i165.photobucket.com/albums/u...ppleMedium.jpg
Finally, bleed your brakes (we did two, but it'd be better to bleed all 4)
here's how the brakes look finished...
http://i165.photobucket.com/albums/u...sideMedium.jpg
http://i165.photobucket.com/albums/u...sideMedium.jpg
Sorry the rotor looks a lil dirty, started raining a lil and tried to clean it off.
Once again, i thank 90crxfreak for helping me install the brakes, rez888 for the sale of the brakes, and the members of GalantForums.com with information and research on the project. :orangesmile: