Changed my rotors today, what a hassle! 

"Wrong Wheel Drive (41%)" (rduncan5678) 04/04/2015 at 21:17 • Filed to: None

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What I thought would be a two hour or so job turned into about 6 hours and it's not really done either. The first problem was figuring out how to actually remove a rotor. I started with the fronts since those should be the easiest ones. Well I found everything to be so rusted on that I could not even get access to the pads. It confused the hell out of me and I eventually figured it but it took like 3 hours to say that I was fully done with both front rotors and pads. The next 3 hours were an even bigger trouble with the rears. Don't get me wrong, I enjoyed the endeavor since I definitely learned a lot but oh man did I underestimate this job lol. The rears were even harder to get off, the bolt method as the official removal method was futile due to rust in the holes. I ended up just needing a big ass mallet to free em up. Liberal force required! Anyways, in the end my rear driver side caliper is actually stuck open (piston will not retract) so I had to put the old pads in and call it a day. I will need to replace that caliper (could rebuild it but the rears are complicated) and now my ebrake is non operable. I will be just going without an ebrake for the week and replacing the caliper next weekend. Nice to have shiny new rotors and much thicker pads though!

OPPOsaurus WRX > Wrong Wheel Drive (41%) 04/04/2015 at 21:25

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nice! I've attempted a few projects like this. the last was actually rotors and pads on my buddy's Outback. One of the bolts was frozen so we use a tree branches a lever to crank on the ratchet. We hear SNAP and unfortunately it wasn't the branch it was the bolt on the caliper. Off to the shop to get the job finished.

norskracer98-ExploringTheOutback > Wrong Wheel Drive (41%) 04/04/2015 at 21:35

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At least your caliper bracket bolt wasn't rusted in or something that it snapped off inside the bracket. Not to mention that same caliper was also frozen. That job took like a whole weekend.

Wrong Wheel Drive (41%) > OPPOsaurus WRX 04/04/2015 at 21:40

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I'm pretty sure my car would have to be on fire or something before I hand it off to a shop. I'm stubborn like that. Even if it takes me multiple days longer, I figure I am learning something and that is invaluable. However, my girlfriend would just sigh and be worried about my cut up hands lol.

Wrong Wheel Drive (41%) > norskracer98-ExploringTheOutback 04/04/2015 at 21:41

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Calipers don't seem very friendly. I guess I could be worse off haha. I Definitely will just replace the whole thing then. Not worth messing with to save $80

OPPOsaurus WRX > Wrong Wheel Drive (41%) 04/04/2015 at 21:47

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once the boltsnapped it was beyond our abilities/tools

Wrong Wheel Drive (41%) > OPPOsaurus WRX 04/04/2015 at 21:51

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Yeah snapped bolts are definitely beyond my willingness to handle. I think I've had nightmares before where a bolt snapped and I had to just throw the whole thing away lol.

Firebird857802 > Wrong Wheel Drive (41%) 04/04/2015 at 21:55

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rear caliper piston may not be frozen.you might have to screw the piston back in to get it to retract. If there are indentations on the piston it may be a tell tale sign it might need to be screwed in. Auto stores will sell this universal cube thing that has 6 sides with 6 different fittings for different cars. You put a 3/8 rachet into it and it screws the piston back in. I know I'm butchering explaining this.

norskracer98-ExploringTheOutback > Wrong Wheel Drive (41%) 04/04/2015 at 21:59

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Yeah, we had to buy a new caliper and a new bracket, not cheap but it was necessary.

Wrong Wheel Drive (41%) > Firebird857802 04/04/2015 at 22:19

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But the screw comes out fully while the piston is still extended. I thought this meant it was likely rusted inside and would not retract further. That pad was especially worn compared to the other side and I believe it had been sticking occasionally. I would have to imagine the caliper is needing replacement. Now that I sort of understand how it functions, it makes even more sense that way. Your solution sounds worth trying again though!

BaconSandwich is tasty. > Wrong Wheel Drive (41%) 04/04/2015 at 22:36

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Just be thankful you don't have drum brakes...

TheVancen- In Pursuit of a Greater Payday and Car Parts > Wrong Wheel Drive (41%) 04/04/2015 at 22:42

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This what happens when you try and do brakes on a car that's been sitting up to the rockers in mud for six years. Ask me how I know, ASK ME HOW I KNOW.

JasonStern911 > Wrong Wheel Drive (41%) 04/05/2015 at 00:27

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As a former RX-8 owner, 6 hours to replace the rotors DIY style sounds awesome.

KusabiSensei - Captain of the Toronto Maple Leafs > Wrong Wheel Drive (41%) 04/05/2015 at 00:38

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The screw action of the piston is the parking brake actuation. I have that system on my Audi, and I hate it.

I have to rent the disk brake kit from AutoZone because the cube doesn't cut it.

DipodomysDeserti > Wrong Wheel Drive (41%) 04/05/2015 at 00:54

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Some cars use a screw in type piston that you need a special tool for. Harbor freight sells a full caliper compression kit for $30 that include dies for a variety of different piston designs. They also sell pullers for $15 which makes getting rusted rotors off a breeze. The best bet for getting tough caliper bolts off is lots of PB blaster and ratcheting wrenches. Pick up a bolt extractor kit while you're at harbor freight and you can get that busted bolt out easy peasey. With the right tools and a little experience, disc brakes are super easy to do. Everything sucks and takes forever the first time.

samssun > Wrong Wheel Drive (41%) 04/05/2015 at 01:12

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When I replaced the stock rotors on my Z, they were rusted on so hard that we went from rubber mallet, to propane torch, to metal hammer, with no luck. But the screws resulted in an almost immediate POP and they came right off.

Sub frame bolts were a little more fun: metal pipe on a breaker bar, pushing against the suspension like a dead lift, and even split a socket.

Ferrero1911 > Wrong Wheel Drive (41%) 04/05/2015 at 03:52

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You're probably not planning on it, but don't wash this car until you get the brakes properly bedded-in or you'll be doing the job over. You know how I know...

Chuck 2(O=[][]=O)2 > Wrong Wheel Drive (41%) 04/05/2015 at 09:50

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Take this

TheRealBicycleBuck > Wrong Wheel Drive (41%) 04/05/2015 at 10:05

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My first brake job was on a '76 Mercury Cougar with drum brakes on the back. The drums were rusted to the hub. It took a prybar and lots of persuasion from a small sledgehammer to get them loose. I also learned a lot of new words from my uncle that day....

Wrong Wheel Drive (41%) > TheVancen- In Pursuit of a Greater Payday and Car Parts 04/06/2015 at 07:35

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That is definitely something I would see on r/justrolledintotheshop

Wrong Wheel Drive (41%) > samssun 04/06/2015 at 07:38

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Yeah that screw method worked beautifully for the front rotors. I managed to use the bolt that was part of the caliper mounting bracket to do it (I imagine it was designed this way on purpose). But the holes of the back ones were so corroded that the threads could not take that bolt in anymore. Big mallet did the trick though thankfully. Lots and lots of crap poured out of the rotors while beating them lol.

Wrong Wheel Drive (41%) > Ferrero1911 04/06/2015 at 07:39

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Yes, I had washed my car earlier in the week and then after Saturday my car was filthy again. I really want to wash it again but I will wait until I fix that caliper.

Wrong Wheel Drive (41%) > BaconSandwich is tasty. 04/06/2015 at 07:41

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Oh yes, I know the pain. My civic had rear drums and I basically just gave up on repairing those. I had a shop replace them once and they just squeak no matter what you do. It just seems like there is no way to properly maintain drum brakes in the same way you can just swap pads on disc brakes. I am very glad to have 4 wheel discs now!

Wrong Wheel Drive (41%) > JasonStern911 04/06/2015 at 07:42

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Haha I could imagine worse I suppose. I just was expecting to take much less time. Now that I know how to do it, I bet I could get it done in like two hours.

Wrong Wheel Drive (41%) > TheRealBicycleBuck 04/06/2015 at 07:42

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Drum brakes make me angry lol

Wrong Wheel Drive (41%) > DipodomysDeserti 04/06/2015 at 07:50

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From what I had read on Miata.net, the only way to retract the rear brake calipers is using the screw in the back. It does adjust the parking brake as well but any other way to retract the caliper could likely damage it. I may try that harbor freight kit though since I believe someone had mentioned rotating and pushing in the piston while also turning the screw in the back.

Wrong Wheel Drive (41%) > DipodomysDeserti 04/06/2015 at 08:30

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http://www.harborfreight.com/disc-brake-pad…

Found that harbor freight kit, it definitely looks like it is worth trying out. It is supposed to screw the piston in which should work. I will try that out today after work and see how that goes!

DipodomysDeserti > Wrong Wheel Drive (41%) 04/06/2015 at 09:35

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That's it. I didn't realize you had a Mazda, which most definitely has the screw type piston. My siste has a 3 and I did the same thing as you when I first changed her pads. I was able to get them with that kit. There's something about Mazdas and rust. Her rotors were also rusted on and I'm in the middle of the desert.

Wrong Wheel Drive (41%) > DipodomysDeserti 04/06/2015 at 11:05

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I posted on Miata.net about using that kit and I had multiple posters just say to replace the caliper if it is stuck like that. Found a remanufactured one (I don't think they are sold new) for around $55 on rockauto (with the core charge and shipping it is like $120 but I will get $60 back eventually). That kit would certainly be useful to have though, wish I just bought it before even starting this repair lol.

DipodomysDeserti > Wrong Wheel Drive (41%) 04/06/2015 at 11:24

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Word. Those guys will definitely know more about Miatas than I do.

TheVancen- In Pursuit of a Greater Payday and Car Parts > Wrong Wheel Drive (41%) 04/06/2015 at 11:40

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Well, when I picked up this car, the guy I bought it from failed to mention it had no brakes, so it literally rolled into his shop. Right into the door actually.

Wrong Wheel Drive (41%) > TheVancen- In Pursuit of a Greater Payday and Car Parts 04/06/2015 at 13:18

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that's gotta be a scary feeling. I always forget to pump the brakes after having the master cylinder cap open. That moment of oh no where is the brakes is always fun.

oldjohn > Chuck 2(O=[][]=O)2 04/09/2015 at 19:57

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I've used Blaster on horrifically rusted bolts and, given a couple of days, the success rate is quite astonishing. Cuts way down on the cutting way down.