2nd Gen "How To" Front brake pad replacement (Gen2)

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MINI Brake Pad Installation Changing your brake pads is a very rewarding DIY project. This tutorial focuses specifically on giving you the...
  1. RonsMinnie
    How To: Front brake pad replacement (Gen2)

    by Ron Pickett (aka RonsMinnie)


    Adapted from OctaneGuy’s Gen1

    https://www.motoringalliance.com/articles/category/1st-generation-mini.6/


    This should be considered an addendum to the above guide; illustrations have changed for Gen2 MINIs.


    Remove the wheels.
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    Remove Brake Hydraulic line from Strut clip.
    Note the narrower line to the left; this is the sensor line (see next step).
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    Remove brake pad wear sensor line from strut clip – this is the electrical wire that signals when brake pads are worn.
    Note the brake fluid line clip to the right is already empty (hydraulic line removed in previous step).
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    The Caliper is held on by two 16mm Bolts (top bolt touched – bottom bolt directly below).
    This view is from the back of the caliper.
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    Remove the two 16mm Bolts – view from top of caliper.
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    Have Resting Place for the Caliper Prepared.
    Do not hang by the lines!!
    I used a blue plastic crate.
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    Lift out the brake sensor being careful with the cooper clip (it is easy to lose).
    On my Gen2 R55 only the driver’s side had the sensor.
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    Lift out the old pads – move to center then lift out.
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    Clean the Caliper Body.
    Get it ready for new pads (brake clean – small wire brush – shop rags).
    [​IMG]

    Inspect the Rotors.
    If they are in good shape -- i.e., are relatively smooth so do not need resurfacing -- sand the Rotors. I used Hawk Pads and Hawk recommends 130 grit paper.
    I started the engine and put car in 5th and let wheel rotate at idle.
    BE CAREFUL – Keep hands outside of rotors so that should something hang-up, you hand will be thrown away from the rotor!
    [​IMG]

    Sanding outer surface of rotor.
    [​IMG]

    Now clean rotors with soap and water.
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    Modified Harbor Freight disk caliper tool.
    Circular hole is cut out to “U” Shape.
    [​IMG]
    Gen2 Calipers have a cross piece between the ends and the tool would
    not fit between as originally designed.

    Compress the caliper piston into the body.
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    Place the new pads into the Caliper.
    Coat ends of pads and caliper piston with anti-squeal gel.
    [​IMG]

    Reconnect Brake Pad Sensor.
    Make sure copper clip is in place.
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    Remount caliper with 16mm bolts (torque to 81 ft/lb) and place brake line and brake sensor lines in strut clips.
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    Put the wheels on and go Motoring!
    -- but bed the pads in first!
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    Original Source

    Written by: RonsMinnie, Dec 26, 2009,

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