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Front disc change
Published by Andy Monty
28-02-2011
Difficulty Level: 4

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Front disc change

This is intended as a guide only if your in any doubt over you ability to do this consult a qualified mechanic as your brakes are rather important


bit of an add on to this guide as im not going over the intimate details of pad removal again for the sake of it

http://www.fiatforum.com/grande-punt...rip-clean.html

So car parked safely wheels chocked hand brake applied

car jacked and axle standed and front wheel off


remove the caliper piston body using a 13mm spanner as in the above guide and the pads (if your new pads come with clips look how the old pad spring clips fit as they only fit on one way)
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clean the piston


clean then remove the brake fluid cap off the header tank

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((DO NOT SPILL ANY FLUID ON YOUR PAINTWORK OR IT WILL REMOVE IT))


next reset the piston ensuring you do not damage the rubber piston seal boot
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i used a g clamp but you can get a special tool to do this from most motor factors
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do this slowly to give the fluid chance to move back without putting any undue pressure on the seals

now i have dropped a bo bo here and not got a photo of this step but i will try and get one when i get chance

you need to undo the caliper carrier using a 19mm socket and remove the 2x bolts

so this bit comes off
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now you can get the disc off


using a T30 Torx bit undo the 2 torx aligning bolts these are commonly seized in so a bit of release oil might help and in my case a hammer and impact driver

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once both are removed either the disc will drop off with a slight pull or need braying round the edge with a hammer to crack any corrosion

clean the stub axle up and coat with copper grease (makes changing them next time easier)
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now get your new disc and clean it well with brake cleaner (they come coated in light oil to prevent rusting in storage)

and refit

apply copper grease to the threads of the torx bolts to make removal easier next time

refit the caliper carrier putting a drop of threadlock on the bolt threads for added security

then fit the new sping retainer clips and new pads greasing the back of them lightly (on the piston side the other side bonds in place with a sticky pad so degrease the caliper where the pad will stick

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ultimately you will be left with this

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19mm caliper across flat carrier bolts Torque 9.9 11.0 (daNm)
13mm across flats caliper bolts torque to 2.7 3.3 (daNm)
T30 torx bolts torque 0.9 1.4 (daNm)


now refit the wheel and do the other side

check fluid doesnt over flow as you reset the piston

once the other side is done pump the brake pedal slowly with the cap off to reset the pistons then refit the cap

now start the car and pump the brakes and check they feel ok

now do several low speed stops in a quiet area to check all is working as it should
AND IMPORTANTLY DRIVE WITH GREAT CARE FOR THE FIRST HUNDRED OR SO MILES OR SO TO GIVE THE NEW PADS AND DISCS TIME TO BED IN AND GET TO FULL POWER AS YOU MIGHT FIND THEM LACKING IN BITE FOR A WHILE i know of a chap who stuffed his car into the back of another having just had his brakes done so it can happen
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Old 06-11-2011   #1
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Re: Front disc change

I Like this post
I did try it my self and it worked fine
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Old 08-11-2011   #2
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Re: Front disc change

Welcome to the forum Fadi
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Old 14-05-2012   #3
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Re: Front disc change

Anyone Else had problems trying to Undo the Aligning Bolts, Mine seem to be Chewwed and won't come out, Any ideas?
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Old 15-05-2012   #4
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Re: Front disc change

drill them out if the heads are gone use a 8mm ish drill bit dead centre just drill far enough so the head falls off then remove the remaing stud with mole grips......


i got mine out using impact driver
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Massive gash
Quote Originally Posted by EmmaM88 View Post
Just a little touch up
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Old 04-12-2012   #5
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Re: Front disc change

What brake discs and pads do you recomend? (im gonna buy them on ebay.. here in chile I could only find korean and chinese ones )

great guide btw

How about these? http://www.ebay.com/itm/FRONT-EBC-UL...item5d34d9a420
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Last edited by etche; 04-12-2012 at 01:04.
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Old 06-12-2012   #6
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Re: Front disc change

watch for fake ebc discs and pads on ebay...


http://www.ebcbrakes.com/cross_drill...d_rotors.shtml
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Old 15-01-2013   #7
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Re: Front disc change

when im changing discs and pads i back off the pads with a big flat head screw driver before i start taking the caliper off.. remember to open your brake fluid reservoir and maybe put some old throw away rags around the opening because the fluid might come out fast
i only do this when im changing the discs aswell because i might mess up the disc when i use this method because im levering a screw driver with it
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Last edited by keepfixinit; 15-01-2013 at 21:25.
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Old 06-02-2013   #8
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Re: Front disc change

hi, i have to do this job on my sisters grande punto but i've looked for the parts on ebay and they say that there are more than one type of disc fitted to this car (vented or solid) and i cant check it until she drives it to my workshop. its a 1.2 8v active 2007 on a 07 plate. could someone tell me what discs are fitted? thanks
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Old 06-02-2013   #9
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Re: Front disc change

don't know the change over date my 06 came with vented.... Will the factors let you order both on sale or return?
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Re: Front disc change

yea they will but i cant really afford to buy 4 disc and i have to go thru the hassle of sending them back without damaging the boxes i think ill just have to have it here for 5min and check why dont they make it easy and fit one type of discs to a 1.2 instead of making it a mission find out thanks for your help anyway mate
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Re: Front disc change

yea they will but i cant really afford to buy 4 disc and i have to go thru the hassle of sending them back without damaging the boxes i think ill just have to have it here for 5min and check why dont they make it easy and fit one type of discs to a 1.2 instead of making it a mission find out thanks for your help anyway mate
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Re: Front disc change

Does any one know the disc thickness that should trigger their replacement? Or is there some other rule of thumb that can be used to indicate that they are due for replacement? You don't just change them when you renew the pads, do you?
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Old 18-08-2013   #13
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Re: Front disc change

There is a disc wear indent on the edge of the disc rotate it looking at the edge of the disc and you will see it
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Old 04-10-2013   #14
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Re: Front disc change

Tried getting discs off but caliper fixing bolts look as if they need a special tool ,nothing like any spanners i have and have been fixing cars for 50 years. Any ideas please?
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