HOW TO- 5.5 Gen Front Brakes on 4th Gen

[95BLKMAX]

I wanted bigger brakes, but I didnt want to spend a fortune (as much as one would spend, say for a Z32 upgrade, or the 6th gen rotors with Z32 calipers, etc...) for just front brakes. Plus I dont autoX, I just do alot of highway spirited driving; so I wanted a beefier setup that wouldnt break the bank.

COST-
Calipers and caliper mounting brackets used- $100
RPT plated/ X-Drilled Rotors, Axxis Metal Master Pads, 2 liters of ATE Blue Racing Fluid- $185shipped
Ubber Drill Bit- $35
Bolts and lockwashers- ~$10

**********************

SPECS-(per 1995 FSM and 2003 FSM)

4th gen Rotors (mm/ inches)
280x22/ 11.02x0.87
5.5 gen Rotors (mm/ inches)
296x24/ 11.65x0.94

4th gen Caliper Pot (mm/ inches)
57.2/ 2.252
5.5 gen Caliper Pot (mm/ inches)
57.2/ 2.252

HOW TO- (I write this assuming you already know how to do a brake job, this how to made with attention to the work specifically related to the conversion process of being able to install these bigger brakes)-

* Remove wheels, calipers (disconnect the lines from them but have a bottle near, they will leak alot of fluid), caliper mounting brackets and pads

* Have this ubber drill bit...

It cost me $35 locally at a "nothing but nuts and bolts- specialized hardware store (Mitchell Supply Company)

also 4 of these Metric bolts with lock washers (stock 4th gen on left, new 5.5gen on right)...

I bought them so long ago I dont recall the specs, so just go to the hardware store with the caliper mounting bracket for thme to check

* With the Ubber drill bit, drill out the two holes on the hub. Try your best to keep it straight. Go slow with the bit at first because if it gets caught up, the drill WILL fling around and it could cause bodily harm depending of how strong of a drill you have. Once it started boring the hole out just go downtown on them. They should look like this afterwards...


* Make a few cuts along the shield's overlap up to the vertical part and with pliers bend the overlap up to vertical. The 5.5gen rotors wont fit otherwise...


* Now with that done, the installation is the exact same as a normal brake job, only that you're using the 5.5 gen parts. Hook up the lines and you will have to bleed ALL 4 calipers. At least with me, I let so much fluid drain that air got into the master cylinder, thus my line for the rear brakes had air, so I had to bleed all 4 corners. Break them in and enjoy the noticeably improved braking over that of the 4th gen parts :-D

[95BLKMAX]

All Buttoned Up!


From a distance with the light against me, lol


Up Close

[xkazik]

nice nice , can you see any difference ?

[Hexon]

Is the that orange hawtness of ksports I see? Neat project. I am interested to hear if you have notice an increase in breaking. And how much did this cost?

[95BLKMAX]

Originally Posted by xkazik

nice nice , can you see any difference ?

Well in all honestly, my old brakes were worn to hell. Pads on the passenger side had about 2mm of material left. Almost down to the metal backing. So yes its definitely worlds better. However, I DO remember what these brakes felt like 3 yrs ago whenI changed them, and yes, these 5.5gen brakes ARE noticeably stronger as far as initial bite and just orerall braking power. Its like adding a turbo to the engine... but to the brakes, LOL. The second time I slammed them from 80 on the highway during the break-in, car felt like it was going to flip forward, lol.

Originally Posted by Hexon

Is the that orange hawtness of ksports I see? Neat project. I am interested to hear if you have notice an increase in breaking. And how much did this cost?

Nope, those are blown 6yo+ AGXs lol. Coilovers are not worth the cost for MY uses.

[phenryiv1]

I am going to add this to the stickys.

Great write-up!

[internetautomar]

so you swapped in 5th gen calipers, and rotors by boring out the original caliper bolt holes and cutting the backing plate?

[black_maxed95]

cool job, good to see something new. But Im wondering about the difference in brake power. The specs show that the 5.5 and 4th gen calipers are the exact same. Wouldnt that mean the braking is the same? Are the 5.5 pads bigger? If not its the same surface area contact and brake pressure, right?

[95BLKMAX]

Originally Posted by black_maxed95

cool job, good to see something new. But Im wondering about the difference in brake power. The specs show that the 5.5 and 4th gen calipers are the exact same. Wouldnt that mean the braking is the same? Are the 5.5 pads bigger? If not its the same surface area contact and brake pressure, right?

Caliper's pot is the same size, but the body of the caliper itself is bigger (as relevant as that may be). The increase in braking power comes front he larger pads (more surface area), and the fact the caliper is located a bit higher away from the center of the hub to clear the larger diameter rotors (more torque). The two combined made it worth it to me, given how little I spent. Great bang for the buck.

**** I added a cost breakdown to the original thread****

[black_maxed95]

ok I understand where the braking power comes from. I wasnt sure if the pads were bigger on a 5.5 and I didnt think about the larger torque. I agree, definately a great bang for the buck. Great alternative for those that dont want/need a bbk.

[NiZMo1o1]

Nice upgrade E !!!

[vilmaxima]

nice upgrade, for a great price. Good job!

[gtr_rider]

I was wondering when you were going to install those things, they were sitting at my house for a hot minute..

[WhiteA32]

How about clearance issues? Are there any?

[Hexon]

Where did you order all of your stuff at that price?

[MDeezy]

well hot damn, seems like every week your installing something new and adding a write up.

good job on these. I might have to look into this

[MOHFpro90]

Goodness man...Im gonna have to talk to you on aim about this. Nice job.

[CapedCadaver]

so, with the whole drill bit thing... would a stepped bit be good to use to get it started (1 step deep) and then finish it off with a straight bit?

[95BLKMAX]

Originally Posted by MOHFpro90

Goodness man...Im gonna have to talk to you on aim about this. Nice job.

go for it

Originally Posted by capedcadaver

so, with the whole drill bit thing... would a stepped bit be good to use to get it started (1 step deep) and then finish it off with a straight bit?

seriously- and I'll give all the credit to the bit's construction, you dont need a step bit at all. This particular bit cut through the iron hub like butter. Just go slow at first. Once you're about 1mm into it, it wont skip around so you can just push it right through no problem

[CapedCadaver]

Originally Posted by 95BLKMAX

go for it


seriously- and I'll give all the credit to the bit's construction, you dont need a step bit at all. This particular bit cut through the iron hub like butter. Just go slow at first. Once you're about 1mm into it, it wont skip around so you can just push it right through no problem

cool. so any-old-bit won't do tho will it? i was wonderin' if you could loan me the thing for $35 and then give $30 back when i mailed it back maybe? kinda 'spensive for something i'm only gonna use once.

[nyc96max]

nice write up and good upgrade

[Blackwind]

how could you make this work for the newer q45 caliper? or is that way off the wall?

[MDeezy]

not off the wall just teh q45/j30 need a wider rotor. I cant say ya or nay for sure but I know those calipers dont bolt up to stock 4g rotors etc, which is why we needed to buy Jeffs brackets

[KRRZ350]

YES! I've been waiting/wondering why no-one has done this!! AWESOME!

Also, a little tip, you can avoid having to bleed all 4 by very lightly pinching the line with visegrips until you are ready to install and bleed.

[Blackwind]

Originally Posted by MDeezy

not off the wall just teh q45/j30 need a wider rotor. I cant say ya or nay for sure but I know those calipers dont bolt up to stock 4g rotors etc, which is why we needed to buy Jeffs brackets

ok. that makes sense. this is a next on my list.

[Nrw]

Any idea if these will fit under the stock SE 16's?