Yorgi s BMW 650i / 645Ci / E63 / E64 6 Series Brake Pad and Rotor Change DIY with Pics

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1 Yorgi s BMW 650i / 645Ci / E63 / E64 6 Series Brake Pad and Rotor Change DIY with Pics Disclaimer: The creator if this DIY is not a BMW technician. This article is provided freely for entertainment purposes only and does not come with any warranty of any kind. Use the information in this article entirely at your own risk. Always wear eye protection while working on any car. NEVER work under a car that is hoisted by a hydraulic jack only. Failure to use jack stands or to use wheel chocks could result in serious injury or death. Ensure the car is on a level and stable surface. The creator of this DIY disclaims all responsibility and liability for the content or accuracy of information provided in this DIY. No rights can be derived from the content of this DIY. The creator of this DIY disclaims all liability for direct or indirect loss of whatever kind and on whatever basis, due to the use of information provided in this DIY. NOTES: Pictures below show a i convertible. The procedure for a 645Ci, 550i, 545i, E9x M3, and E6x 7 Series should be relatively the same. Part numbers are based on information available at time of article creation. Check with your dealer to ensure the correct parts are used for your application. I try to create instructions with enough detail for the first timer DIY er. The experienced DIY er can probably make do with the pictures and bolded text only. If this is your first brake pad change it should take about 2 hours, an experienced DIY er can probably finish in less than 1 hour, including removal and re-install of wheels. Rear parking brake shoe replacement is not covered in this DIY since I have never seen a car which required new brake shoes. Some pictures below show the brake calipers removed from the car which was possible since I was also installing stainless steel brake lines. Do not remove calipers during brake pad changes or you will have to bleed the brakes after the pad install. A. REQUIRED Supplies - pre-purchase from the dealer or online: Prices below are full dealer list in USD; you can find parts online for approximately 33% less than full list. Brake Pads FRONT for E63/E64 - BMW Part # or ($159) (JURID pads) REAR for E63/E64 BMW Part # ($130) (Textar pads) Brake pad wear sensors The BMW TIS recommends replacing these during every brake job. You may break sensors on removal so it s a good idea to have a set on hand before you begin, even if you plan on re-using the sensors. If your BRAKE light is lit on the instrument cluster you must replace the sensors. FRONT LEFT - BMW Part# ($28) REAR RIGHT - BMW Part# ($29) BMW OEM Brake Pad Paste BMW brand anti-squeal paste available at the dealer (great product) - Part # ($1) Good alternatives: GWR Ceramlub 2800 Purple Permatex Ceramic Extreme Brake Lubricant Brake cleaner spray Copper or aluminum anti-seize paste Good alternate brake pads: See Yorgi s Brake Pad FAQ for aftermarket alternatives NOTE: The E63/E64 use the exact same brake pads (front & rear) as the E92 M3. When searching for replacement pads you will find a much larger selection available if you search for E92 M3 pads. For whatever reason, most sites including Zeckhausen list a limited number of pads for the 6 series. The front brake pad FMSI shape is D918 (HAWK pad shape is HB551) The rear brake pad FMSI shape is D919 (HAWK pad shape is HB630) Yorgi s 6er Brake Pad and Rotor DIY Page 1 of 55

2 B. OPTIONAL Supplies dependant on condition of existing components Brake Rotors If required these are for 645Ci / 650i. 630i are different. FRONT - BMW Part# ($180) REAR - BMW Part# ($144) Brake Rotor retention screws 1 per rotor BMW Part# ($1) Brake Caliper Piston Repair Kit (if dust boots or pistons are damaged) 1 per caliper FRONT - BMW Part# ($25) REAR - BMW Part# ($40) Brake Caliper Guide Pins - Replace if damaged FRONT UPPER (shorter) BMW Part # ($20) FRONT LOWER (longer) BMW Part # ($21) REAR x2 per caliper BMW Part # ($20) Brake Fluid may be needed to top up reservoir after pad install. You can use any DOT 4 fluid. Ate Typ200 is a good choice. Jack Pad Before ordering brake parts, check your car to ensure all 4 jack pads are still attached to the car. These tend to fall off. If you are missing jack pads order them along with the brake pads. FRONT JACK PAD BMW Part # ($15) REAR JACK PAD BMW Part # ($15) Yorgi s 6er Brake Pad and Rotor DIY Page 2 of 55

3 C. REQUIRED Tools for Brake Pad Change: Floor jack 17mm deep socket 7mm hex socket with extension (Allen head socket) T25 Torx key for cabin air filter cover (removed for brake fluid reservoir access) 13mm socket for cabin air filter cover 8 or larger C-clamp Large blade screwdriver or small pry bar Small blade screwdriver Coat hanger or other heavy wire - to hang caliper on spring while working on pads Brake rotor vernier caliper. OR micrometer with a range of 1-2. Trouble lamp Half-round metal hand file Torque wrench capable of 88 lb-ft, 22 lb-ft and 12 lb-ft Ratchet wrench for sockets Rags / shop towels Wheel chocks Wire brushes for cleaning calipers and carriers D. ADDITIONAL REQUIRED Tools for Rotors: 18mm socket required if changing rotors 6mm hex socket (Allen head socket) required if changing rotors Yorgi s 6er Brake Pad and Rotor DIY Page 3 of 55

4 E. OPTIONAL Tools: Mechanix Wear type gloves or disposable nitrile gloves Impact drill or cross wrench for quick removal and install of wheel bolts Disposable face mask filter to prevent inhalation of brake pad dust during cleaning of caliper Rubber mallet to remove sticking rotors Tightening Torques From the BMW TIS: Wheel bolts: 120 Nm +/- 10 Nm (88 lb-ft +/- 7 lb-ft) Caliper Carrier bolts: 110 Nm (81 lb-ft) Guide Pins: 30 Nm (22 lb-ft) Rotor set screw/retaining bolt: 16 Nm (12 lb-ft) F. Before you begin: Please be aware that mistakes made during brake pad replacement can result in catastrophic failure of the brakes. If you do not feel comfortable that you have the skills required to perform the steps below please leave your brake repairs to a qualified mechanic. Do not skip steps below that involve checking the condition of parts (rotors, sensors, guide pins). Failure to replace worn parts cold result in the failure of the braking system. TIP: It is a good idea to pull one front wheel and one rear wheel to measure rotor thickness before you order new brake pads. This will allow you to add rotors to your order if necessary so you can complete both pads and rotors replacement at the same time. Also check your 4 jack pads to ensure none are missing. Yorgi s 6er Brake Pad and Rotor DIY Page 4 of 55

5 G. Front Brake Pad Change Steps: G1. Remove front driver side wheel While the car is still on the ground, use a breaker bar with a 17mm extended socket to loosen the 5 wheel bolts. Break the bolt loose using a star pattern then gently retighten to the point where the bolt can still be removed once the wheel is off the ground. If you have wheel locks and don t know where the key is, check under the trunk mat where the battery and tools are located which is the standard storage location. TIP: Cover the socket with black tape to prevent marring the wheels. Engage the parking brake and chock the rear wheel on the opposite side of the car you are jacking to prevent the car from moving while on the jack. Raise the front wheel using a hydraulic jack on the front left jacking point. See IMAGE #05. Use a cross wrench or cordless impact wrench to fully remove the 5 wheel bolts. If the wheel is stuck to the hub after removing the 5 bolts, use a rubber mallet to hit the outer edges of the wheel until it comes loose. You can also sit in front of the wheel and use the heel of a running shoe to kick the outer edges of the tire until the wheel come loose. TIP: During removal of the last bolt, press the wheel against the hub to prevent it from falling off the hub. You don t want the wheel falling and hitting the brake caliper on the way down. Yorgi s 6er Brake Pad and Rotor DIY Page 5 of 55

6 G2. Remove Spring Clip Use a large blade screwdriver or small pry bar to remove spring clip from caliper. Pry the middle of the clip horizontally back towards the rear of the car until the retaining lug in the middle of the clip is exposed, then pull the clip towards you. Yorgi s 6er Brake Pad and Rotor DIY Page 6 of 55

7 G3. Remove Guide Pins Pry off the two plastic caps covering the guide pins. See IMAGE #7. Using a 7mm hex socket, remove the upper and lower guide pins. Yorgi s 6er Brake Pad and Rotor DIY Page 7 of 55

8 G4. Compress Piston back into Caliper The piston must be fully pushed back into the caliper to make room for the thicker replacement pads. You also need to push the piston in to get the caliper off the carrier if there is a wear lip on the outer edge of the rotor. Place an 8 C-clamp as illustrated in IMAGE #10. Be careful not to pinch wires or the bleed valve at the back of the caliper. Tighten the clamp until the piston is fully seated in the caliper. There should be only mild resistance as you tighten the clamp, if not check the positioning of the C-clamp. TIP: Keep an eye on the brake fluid reservoir for fluid levels before and after each piston is compressed. If the fluid level rises to near overflow remove some fluid from the reservoir. Brake fluid is an excellent paint stripper and will severely damage paint if spilled. See Section J below for details on how to gain access to the brake fluid reservoir. Yorgi s 6er Brake Pad and Rotor DIY Page 8 of 55

9 G5. Disconnect Brake Pad Wear Sensor (Front Left and Rear Right wheels only) BMW TIS Note: The brake pad wear sensor must be replaced once it has been removed (brake pad wear sensor loses its retention capability in the brake pad) If you are a die-hard believer in BMW s TIS recommendations, then always replace sensors when doing brake pads. I examine the sensor for wear and if it s in good condition I reuse it. It is still a very good idea to have new sensors on hand in case you break them during removal. They can get brittle over time. Yorgi s 6er Brake Pad and Rotor DIY Page 9 of 55

10 Follow the sensor wire back to the enclosure. Open cover of housing and unplug old sensor and replace with new sensor. There is a small push button at the base of the plug that must be pushed to release the plug. Use the old sensor wire to route the new wire back to the caliper. Do not install the green end of the sensor into the pad at this point. Yorgi s 6er Brake Pad and Rotor DIY Page 10 of 55

11 Yorgi s 6er Brake Pad and Rotor DIY Page 11 of 55

12 Yorgi s 6er Brake Pad and Rotor DIY Page 12 of 55

13 G6. Remove Brake Caliper from the Brake Carrier and hang it from the suspension spring Wiggle the caliper off the carrier by pulling towards the back of the car. Never let the caliper hang by the brake line - you could damage the lines which may result in bake failure. See IMAGE #19 for an example of how to hang the caliper by the suspension spring. You can also place the caliper on an upside down bucket or other suitable stand. Yorgi s 6er Brake Pad and Rotor DIY Page 13 of 55

14 If the caliper does not come off easily the piston is probably not fully retracted. Repeat Step G4 to ensure the piston is compressed. Yorgi s 6er Brake Pad and Rotor DIY Page 14 of 55

15 G7. Fully compress piston back into caliper if necessary Once the caliper has been removed look at the piston and confirm it is fully compressed. If not use the C-clamp to push on the inner brake pad until the piston is fully retracted. To prevent damaging the piston, NEVER push directly on the face of the piston, always use an old pad or even a block of wood between the clamp and piston face. Yorgi s 6er Brake Pad and Rotor DIY Page 15 of 55

16 G8. Clean brake carrier, caliper and guide pins. Inspect condition of piston rubber boot. Remove both brake pads from the caliper. Examine the condition of the rubber boot and piston face. If any rips are visible in the rubber or if the piston face contains heavy gouges or a large amount of rust order a caliper rebuild kit from BMW. It is important to thoroughly clean the surface of the piston and the inside of the caliper directly across from the piston. These two areas contact the backs of the pads and if they are not clean and smooth brake squeal can occur. Guide pins should always be removed and thoroughly cleaned to ensure smooth operation of the caliper. The caliper slides on these pins and will bind if they are overly dirty resulting in rapid pad wear and possibly squeal. DO NOT grease the guide pins. Unlike other cars which have metal-on-metal pins BMW uses a rubber-on-metal design that will bind the calipers if grease is used on the pins. BMW TIS Note: Replace guide screws which are not in perfect condition. If you cannot get the pins clean or if you notice groves in the pins once they are cleaned replace the pins, they are not expensive. Cleaning guide pins and the caliper-to-pad contact areas is dirty work but failure to do this will contribute to the likelihood of brake squeal and rapid pad wear. Dirty and binding calipers are a major cause of squealing. Yorgi s 6er Brake Pad and Rotor DIY Page 16 of 55

17 TIP: Use brake cleaner, wire brushes and an old credit card to scrape off deposits on guide pins. I use small brass brushes to clean the caliper-to-pad contact points thoroughly. A small blade screwdriver can be used with light pressure to scrape off large deposits. Spray brake cleaner fluid liberally as you go. See IMAGE #21 and IMAGE #23 for a before/dirty and after/clean caliper and pins. Yorgi s 6er Brake Pad and Rotor DIY Page 17 of 55

18 TIP: Place newspaper under the caliper to catch brake pad dust/grime that falls during cleaning. It is also a good idea to wear a face mask and eye protection while cleaning the calipers since quite a bit of dust can be kicked up if the calipers are very dirty. G9. Check Brake Rotor thickness and runout The minimum allowable rotor thickness is stamped on the rotor hat. See IMAGE #24 Use a brake rotor vernier caliper (available on ebay for $30) to measure rotor thickness. A brake rotor vernier caliper will reach over any outer lip caused by worn rotors. You can also use a micrometer with a 1-2 range to measure rotor thickness. As a workaround you can use a standard vernier caliper with two spacers placed on each face of the rotor then subtract the thickness of the spacers to get your reading. If the rotor is below the stamped minimum then the rotors must be replaced. See Step G10. Yorgi s 6er Brake Pad and Rotor DIY Page 18 of 55

19 OPTIONAL: measure rotor runout In addition to thickness, rotors can be checked for runout (warpage). A dial indicator with magnetic stand can be found on ebay for ~ $40. Large steel surfaces are rare on the 6er, so I used the carrier for the magnetic base. Yorgi s 6er Brake Pad and Rotor DIY Page 19 of 55

20 G10. OPTIONAL Replace Brake Rotors If Necessary Replace brake rotors if thickness is found to be below the minimum thickness stamped on the rotor hat. Always replace rotors in pairs. Remove the two caliper carrier bolts using an 18mm socket or 18mm wrench and remove carrier from steering knuckle. Yorgi s 6er Brake Pad and Rotor DIY Page 20 of 55

21 TIP: If you are removing the carriers for a rotor install, clean and lube carriers while they are off the car. Remove rotor retaining screw from rotor with a 6mm hex socket. Keep pressure on the rotor with one hand to prevent it from falling off the hub while loosening the screw. Yorgi s 6er Brake Pad and Rotor DIY Page 21 of 55

22 Pull rotor off hub. If it sticks use a rubber mallet on the rotor hat to loosen the caliper. Don t hit the rotor ring with the rubber mallet. Clean the face of the hub with a wire brush. Debris on the face of the hub can cause wheel vibrations or a warped rotor feeling when braking. If retaining screw is rusty replace it. Seized rotor retaining screws are a common problem and will require drilling out if they get bad. If I see any rust at all on the retaining screw I replace them. At $1 it is cheap insurance against seized screws. Yorgi s 6er Brake Pad and Rotor DIY Page 22 of 55

23 Install new rotor on hub. Use anti-seize compound on retaining screw threads and torque to 16 Nm (12 lb-ft). Install caliper carrier and torque bolts to 110 Nm (81 lb-ft). TIP: If you are using anti-squeal paste on calipers, see IMAGE #38 and apply paste now before installing the carrier. G11. Prep Brake pads for installation OPTIONAL: To help prevent squeal use a metal file to gently round the outer edges of the pads. This helps prevent pad vibration due to sharp leading edges coming in contact with the rotor. No need to take a large amount of material off, just gently round the edges. See IMAGE #35. Yorgi s 6er Brake Pad and Rotor DIY Page 23 of 55

24 Yorgi s 6er Brake Pad and Rotor DIY Page 24 of 55

25 G12. Apply Anti-Squeal Compound to Caliper and Carrier Apply a thin coat of anti-squeal compound to the piston surface being careful not to get any on the rubber seal which can cause swelling. Apply a thin coat of anti-squeal compound to the smooth surface directly across from piston (where the back of the outside pad comes into contact with the caliper) and to the caliper hammer heads - where the outer pad ears will make contact. Yorgi s 6er Brake Pad and Rotor DIY Page 25 of 55

26 Apply a thin coat of anti-squeal compound to the caliper carrier at the pad contact points. Avoid getting paste on rotor. If grease gets on rotor, use brake cleaning spray to clean rotor. TIP: If carriers were not removed for new rotor install, use masking tape to protect rotor from grease. Yorgi s 6er Brake Pad and Rotor DIY Page 26 of 55

27 G13. Install brake pads and caliper Push the inner pad, the one with 3 fingers on the back of the pad, into the piston. Push on the outer pad, with 2 fingers, onto the other side of the caliper. Yorgi s 6er Brake Pad and Rotor DIY Page 27 of 55

28 With the new pads installed, push the caliper back onto the caliper carrier. Yorgi s 6er Brake Pad and Rotor DIY Page 28 of 55

29 G14. Install Guide Pins and caps Torque to 30Nm (22 lb-ft). Do not over tighten the guide pins and ensure they are clean before installing. Install the 2 plastic cover caps. NOTE: the longer pin goes on the bottom of the caliper. G15. Install brake pad wear sensor The new sensor should have been plugged into the enclosure in Step G5. Take the green sensor end and plug it into the notch on the top of the inner brake pad. It may take some wiggling and force to get it to snap in fully. Yorgi s 6er Brake Pad and Rotor DIY Page 29 of 55

30 G16. Install spring retaining clip Position the two outer ends of the clip first then push firmly towards the back of the car on the middle of the clip to engage the lug. You can use the prybar to help push back the clip before inserting the lug. Once in place you can tap the clip with a rubber mallet to ensure it is fully seated. Yorgi s 6er Brake Pad and Rotor DIY Page 30 of 55

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