In the February 2004 issue of ec, we put Autotech's R32 brake conversion to the test, and it passed with flying colors. To save space in the magazine, we're presenting the how-to procedure here online.
Since we did the front brakes in the field, sans photo equipment, the disassembly procedure will be delivered in shorthand by means of an exploded diagram. You should have a Bentley factory workshop manual on hand when working on your vehicle, and leave the job to a professional if it seems out of your league.
Removing the Front Brakes
Begin by removing the anti-rattle clip #5. Remove the two bolts #9 holding the caliper to the carrier. This will allow the caliper have (#7) to be pulled free. Remove brake pads (#3 & #4.) On the driver's side, you will have to unfasten the brake wear indicator wire. Since the R32 pads do not have this wire, you should tape up the connector at the strut housing. The caliper should not be allowed to dangle on the brake hose. Support its weight with a piece of wire while you're removing the caliper carrier bolts (#11.) Finally, remove the banjo bolt for the brake hose (#10.) The caliper and carrier are now removed. Finally, remove the small allen bolt locating the rotor on the hub (#1.) Remove the rotor.
Installing the Front Brakes
Locate the new, larger R32...
Locate the new, larger R32 caliper on the hub using the same set screw.
The front caliper carriers...
The front caliper carriers are side-specific and should be torqued to the values listed in your shop manual.
The caliper should be filled...
The caliper should be filled with pads and slipped onto the carrier.
The caliper is attached to...
The caliper is attached to the carrier with two hex bolts.
There is an anti-rattle clip...
There is an anti-rattle clip that needs to fit into grooves. Use a pointed object to shove it in.
The front brakes finished....
The front brakes finished. Of course the banjo bolt holding the hose should be fastened as well.
Removing the Rear BrakesInstalling the rear brakes is a bit more difficult as the rear hubs must be removed. Because they're coming off, you'll most likely need to replace the bearings as they're often damaged when pulling. At the very least, plan ahead and have the parts handy.
First remove the dust cap...
First remove the dust cap in the center of the hub.
The parking brake lever needs...
The parking brake lever needs to be pulled down and the cable end freed. There is a clip that holds the bowden tube to the caliper that needs to be removed.
There are two bolts holding...
There are two bolts holding the caliper together. Use a thin wrench to hold the guide pins while removing the bolts
With the two bolts removed,...
With the two bolts removed, the caliper and pads can be pulled free. Next remove the caliper carrier.
The hub is fastened to the...
The hub is fastened to the spindle by means of a large nut.
The rear rotor can be removed...
The rear rotor can be removed before using a puller on the hub.
If the hub and rotor are pulled...
If the hub and rotor are pulled together, remove the set screw to separate.
With the hub removed, the...
With the hub removed, the brake backing plate can be unbolted. These large bolts also locate the spindle on the rear beam.
The bolts fastening the spindle...
The bolts fastening the spindle and new brake backing plate need to be torqued down to the proper values.
The hub being attached. It...
The hub being attached. It requires a great deal of torque.
The rotor should be cleaned...
The rotor should be cleaned and located on the hub with the set screw
There is a replacement carrier...
There is a replacement carrier included with the Autotech kit.
The new brake pads being ...
The new brake pads being fitted.
The caliper being mounted...
The caliper being mounted over the pads and onto its carrier
Like the old, the new caliper...
Like the old, the new caliper uses two bolts to fasten it to the sliding bolts on the carrier.
A screwdriver is used to lever...
A screwdriver is used to lever the parking brake lever so the cable end can be fitted.
The brake cable is fastened...
The brake cable is fastened with this small clip.
The hose on the old caliper...
The hose on the old caliper can now be removed.
There is a small plug in the...
There is a small plug in the new caliper that must be removed before installing the hose.
The finished product.