|Rover 800 820 825 827 Rear Brake Discs and Pads.|
Car: 1999 Rover 800 820 Auto Fastback
Colour: Charcoal Grey / Black
Front brakes are always bigger than the rear brakes on cars, and so you would think that the rear brakes would cost less when it comes to replacement.
The front brakes are bigger, because they are required to provide most of the stopping power, as the weight of the vehicle is thrown forward during deceleration. Having bigger brakes at the front of a vehicle rather than at the rear, also stops the rear end of the car from skidding out under normal use of the brakes!
Even though the front brakes are bigger the extra forces exerted on them cause them to wear out far quicker than the rear ones ever do.
This results in the need for far more sets of front brake discs & pads being manufactured and as such brings the costs of the larger front brakes usually down below the costs of the smaller rear brakes!
We decided to replace the rear discs on this car because the car had now done over 93,000 miles and we had replaced them the first time at 46,000 miles. The first time we had changed them we bought the replacements from Unipart. This time we purchased a pair of rear brake discs far cheaper by buying them off ebay. By shopping on ebay, we managed to obtain a set of boxed Unipart discs and got them for £26 including delivery!
This time when we opened the box though we were a little surprised to see that the discs had primer on the non-contact surfaces to help prevent the onslaught of rust in the future. We painted over this primer with a coat of black smooth Hammerite, as further protection for them. Painting them with the Hammerite only took a few minutes with a brush and they were then dry within an hour ready for fitting.
Swapping over brake discs and pads is not as daunting as it may first seem, the biggest problem is removing any stubborn bolts and screws, and the most time consuming thing is usually cleaning parts prior to re-fitting them.
The pistons on the rear brake calipers of the Rover 800 do not push in like the pistons on the front brake calipers do. Instead you have to rotate them back in. To do this you can use any tools, rather than purchasing a special tool for the job. In the past we have simply used a flat metal bar to turn the piston in, but now we have found we have a bike tool that is ideal for this purpose.
Although we have changed the discs for new ones, the EBC pads we are using on the rear brakes have not been on for that long, and so we are just re-fitting them in this case.
After removing and inspecting the old rear discs, they seem to have had very little wear on them. The excessive wear we had on the original rear discs at 46,000 miles, must of been mostly down to the first owner, using much harder braking! Still it's always nice to have a new set fitted.
Look after your car, and it will look after you!
Rover 800 'Unipart' Rear Brake Discs, bought for £17.50 + p&p off ebay. Cheap!
Five Minutes later after a quick brush with some smooth Hammerite that we had handy.
Here is a photo one of the old rear brakes after the front of the car has been chocked and the rear of the car has been supported on axle stands.
There are 4 bolts to remove on a caliper, remove the small top & bottom bolt first, to separate the caliper into two parts.
Pull the caliper away, and hang it out of the way, so that the brake fluid pipes do not get strained.
Remove the old brake pads and shims.
(If you are only replacing the pads, just clean the shims and caliper pins and then put things back together at this stage, otherwise remove the 2 larger bolts).
You may need a socket set or strong arm to loosen the bolts to begin with, as they are usually very tight, if they have not been regularly serviced. (It might also be easier to remove the cailper pins out of the way first).
With the caliper removed, you can now remove the brake disc. This usually has a screw or two to hold it in place, they can be very difficult to get out and may need an impact screwdriver to begin with, before you can use an ordinary screwdriver on them. Hopefully you can get them out without having to drill them out!
After removing the screw, a hammer was used to give a few good whacks to the rear of the brake disc to help free it before it would come off.
The caliper can be given a good clean at any stage during this whole process.
The ABS sensor & cog have been hidden behind the brake disc and this is always a great opportunity to give the teeth on the cog a good wire brushing and general clean up, not forgetting to give the sensor a light wipe over too.
The new disc has been put in place and the holding screw put back in place.
Next you will need to push the rear piston back in a little to help you put the caliper together easier. You will have to push it in further if fitting new brake pads (& may have to check the brake fluid level under the bonnet, as a little may need to be drained off). Unlike the front brakes on the Rover 800 that simply push back in and can be squashed back in using a G-clamp or metal bars, the rear brake calipers rotate back in. There is a special tool for this (apparently!), although we turn them back in using anything from pliers to a metal bar (although do be careful, whatever you use)(you should not use anything that may damage the dust seals or your fingers!). Although we now use a bike tool that seems to fit perfectly!
The piston should be turned back in so that the slots in the piston head are lined up like they were before, this is because otherwise they do not line up correctly with the small stub on the back of the inner brake pad. (always check the inner pad is flat to the piston and disc after you refit everything). Do not worry about turning the piston in an extra turn or two, it will come back out later when you press the brakes.
The caliper pins, brake pad shims, and all 4 bolts have been cleaned and each was smeared with a small amount of copperease which helps them all fit and move easier, and always makes them easier for removal the next time. We refitted the EBC rear pads which we were already using on this car as they had not been used for long and did not require replacing.
After fitting press the foot pedal a few times to bring the brake pads tight to the discs. Then refit the wheels. Remember to drive more carefully after fitting any new brakes until they have bed in properly and you can see new wear on the discs.