General Upgrading from 262mm to 282mm vented brakes for 200/400/25/ZR - MG-Rover.org Forums
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post #1 of 44 (permalink) Old 05-02-2009, 07:37 Thread Starter
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Upgrading from 262mm to 282mm vented brakes for 200/400/25/ZR

I originally posted a rough version of this in the 200/25/ZR section, but thought it better if I reposted it in here in a lot more detail as a guide, as hopefully it will help anyone thinking about doing the brake upgrade, (Hottubs guide on changing discs pads put the thought in my head)

282mm brake set ups can be found on any MG ZR 160/ MG ZS 180's, and are a straight bolt on fit, no modification is required to fit these to any Rover 200/25/MG ZR, im pretty sure these would fit 400's and other model ZS's though im not sure so will leave it for someone else to confirm.
Just to note, new 282mm discs and pads will also be needed when fitting the new callipers/carriers, you can not use your old discs and pads.

Worth mentioning is that the brake set up from a 620Ti (Which is also 282mm) will also fit, but will require slight modification to the carriers, 3mm's will need grinding off each side in the areas shown in the picture below.



The benefit to the 620Ti brakes, is that the pads are slightly bigger than the other 282mm brakes, and as such will have a larger surface area touching the discs, thus giving better breaking ( again I haven't got these brakes, so can only comment on what I have read)

I upgraded a members brakes, he had the 262mm solid disc brake set up, and he commented on just how rubbish they were.

The awfully rubbish standard 262mm solid disc brakes.


First of all I clamped the brake hose, with this little tool (Brake hose clamp, these can be bought from most Motor shops, theirs nothing special about this one).


Once the hose was clamped, I then removed the hose banjo bolt that attaches the hose to the calliper, again this doesn't require anything special doing, treat it as a standard bolt that you would remove from anywhere else on the car.



Once this was undone, and the excess brake fluid drained, I then removed the 2 carrier bolts.


Once these 2 bolts were removed the calliper and carrier came away as one unit, and I removed the old disc, by removing the 2 retaining screws that can be seen on the picture below this one.


I then fitted the new 282mm vented discs, by screwing in the disc retaining screws.


I then refitted the carrier by fixing the 2 bolts I showed earlier, and then refitted the calliper to the carrier, by these 2 bolts, one upper and one lower.
The callipers were already painted red before I was given them, and I have to say the job was shocking, as you can see the paint is all over the rubber protector, the callipers took over 4 hours to strip the old paint off and get rid of the layers of rust, before I repainted them.



I then slotted in the brake pads, i always apply a small amount of copper grease to the back of pads before I refit them, this helps reduce brake squeals, just be very careful not to put too much on, so that it could push out over the edges and contaminate the pad and/or discs, apply it with a finger to make sure.



You can see the amount of excess fluid that drained when I removed the old brakes, as the picture shows really, there isn't much excess fluid drained.
I refitted the brake pipe to the calliper, using the same banjo bolt I removed earlier, tighten the bolt to 34NM.



By this time Mick had done a runner and left me an Tim to fend for ourselves, so I couldn't take pictures of when I bled the brakes, and refilled with new brake fluid. The bleeding of brakes is very simple to do though, I used a draper brake bleeding kit that costs 6, apologies for the next advice not being more detailed but i did this a few months ago and cant remember bolt sizes etc.


I used DOT4 brake fluid
1) I opened up the brake reservoir cap, located in the engine bay
2) On the calliper itself is a little bleed nipple, these are usually covered with a small rubber cap, you can just see it in the picture below, its in the middle right hand side of the picture, just at the side of the clamp. The nipple is basically a nut, I placed the bleed kit pipe on the nipple then undid the nut a little, don't undo it too much.
4) Next make sure the engine is running, you will also need another person to watch the pipe connected to the nipple, and to keep topping up the brake fluid reservoir as needed.
5) With the above in place slowly press the brake pedal, the slowly release it, while you are doing this, the person watching the bleed tube connected to the nipple, will be able to see air bubbles coming out of the calliper and travelling along the clear tubing, you repeat this procedure until the air bubbles stop coming from the calliper (remember to keep topping up the brake fluid as your basically pumping out the fluid you currently have in your reservoir tank in the engine bay)
6) Tighten up the nipple nut (10nm), and replace the rubber sleeve, be careful with brake fluid it can be pretty harmful stuff.

I will warn people reading the above bleeding guide, this guide is here based upon my brake upgrade conversion, and is not the complete article regarding the bleeding of brakes on a car, if you want a complete guide pm me and ill do a separate write up for the people who require this



And finally the complete article.



If i've missed anything let me know so I can amend/add stuff, and if anyone has any questions ask away.

Last edited by Ste; 16-02-2009 at 15:53.
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post #2 of 44 (permalink) Old 05-02-2009, 14:41
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Nice work Ste.

Who's this "Hottubs" fella that you speak of!
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post #3 of 44 (permalink) Old 05-02-2009, 15:18 Thread Starter
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Nice work Ste.

Who's this "Hottubs" fella that you speak of!
Its my pet name for you my very sexy friend.
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post #4 of 44 (permalink) Old 05-02-2009, 15:28
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Its my pet name for you my very sexy friend.
Oooh baby.

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post #5 of 44 (permalink) Old 05-02-2009, 16:36
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i need new break caliper's what sort of breaks should i go for and were from?
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post #6 of 44 (permalink) Old 05-02-2009, 17:04 Thread Starter
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After fitting a couple of 282mm vented brake setups, id recommend them over the 262mm solid brakes, the callipers/carriers can be got from either the MG ZR 160 or MG ZS 180, both use the exact same brakes.

If you cant find the above then id recommend going for the 262mm vented brakes, the fitting procedure is the same as i've outlined in my guide.
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post #7 of 44 (permalink) Old 26-04-2010, 14:51
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Can you give advice on bleeding after conversion as I will be peforming a 262mm upgrade myself for the first time and i know diddley squat what i am doing.

Last edited by Stu; 26-04-2010 at 20:00.
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post #8 of 44 (permalink) Old 08-06-2011, 11:35
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qiuck question will rover 800 front brakes fit a 25 ? there 4 stud
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post #9 of 44 (permalink) Old 08-06-2011, 20:16
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qiuck question will rover 800 front brakes fit a 25 ? there 4 stud
They may be 4 stud but they don't have the same PCD.
The disks certainly wouldn't fit at all.
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post #10 of 44 (permalink) Old 30-10-2011, 07:57
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What size wheels will this upgrade fit? Can you still use 14" or do you have to go to 15 or even 16"?
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post #11 of 44 (permalink) Old 30-10-2011, 08:32
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nice write up, i'll keep it in mind when i'm upgrading mine to vented disks

very much doubt 14's will fit over them, think you might just get 15's over but best off with 16+
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post #12 of 44 (permalink) Old 30-10-2011, 09:31
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yup you ned 16inch plus to give you clearance over the brake calliper. there might be some aftermarket 15's that would fit but you would have to check, you might be able to use spaces but again thats down to you to check
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post #13 of 44 (permalink) Old 15-11-2011, 19:28
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Ok, thanks for the info. Looking at keeping 14" wheels for the new rally car (less unsprung weight, less weight carried for the spares, less stress on the drivetrain, and no degradation of the gearing), so need to keep the 262mm setup.

As an aside, when people mention the 'caliper carrier' I assume that is the rectangular 'frame' as seen below the calipers in this pic? (yes I know this is a pic of the 282mm setup). When we converted the old wedge rally car to vented setup, I seem to remember needing to change the entire 'stub axle' (bottom bit of the strut), as the carrier was slightly 'longer' compared with the unvented setup. Is the bubble a different design?

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post #14 of 44 (permalink) Old 15-11-2011, 19:32
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Yes, that is correct.
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post #15 of 44 (permalink) Old 13-12-2011, 09:17
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Originally Posted by Ste View Post
After fitting a couple of 282mm vented brake setups, id recommend them over the 262mm solid brakes, the callipers/carriers can be got from either the MG ZR 160 or MG ZS 180, both use the exact same brakes.

If you cant find the above then id recommend going for the 262mm vented brakes, the fitting procedure is the same as i've outlined in my guide.
I would definitely agree with this I have Public Liability Insurance 262mm vented brakes and I absolutely love them!!

Last edited by kashat; 07-02-2012 at 09:35.
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post #16 of 44 (permalink) Old 14-12-2011, 14:42
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i use a calipers from 820ti and brake disks from MG ZR





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post #17 of 44 (permalink) Old 08-01-2012, 20:03
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I'm looking at doing this to my rover 25 1.6 xreg, i can only really find the vented discs off the rover 25 2.0 td these are 262mm is this a direct swap? And does this caliper only fit a 262mm and not a 282mm off the mgzr 160?
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post #18 of 44 (permalink) Old 08-01-2012, 20:29
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the parts are a straight swap, need calipers, carriers, new disks and pads.

the 282 vented setup is different again, so for 282 vented disks you'd need to fit the appropriate parts for that size disk.
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post #19 of 44 (permalink) Old 08-01-2012, 21:34
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So sorry to get this right for the 282mm set up I'd need the MG ZR160 set up or the MG ZS 180? And for the 262mm I'd need the Rover 25 2.0 td? Also the 282mm discs from the MG are not suitable for use with the Rover 2.0 td caliper? (sorry for repeating myself) I just want to buy once and not mess around as I use my car every day.
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post #20 of 44 (permalink) Old 08-01-2012, 22:16
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that's how i understand it,
if you want the 282 setup you'll need to make sure all parts came from a car with the 282's.
calipers, carriers and disks are suitable for one size only.
the 262 disks are a little too small for the 282 setup and the carriers will foul the 282 disks
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