How-to: Cheap brake upgrade

Has anybody performed the rear upgrade on a 2.0i E85? The fronts were no problem at all, but the rears are an issue.

I have sourced the calipers from a 325i and some 294mm drilled Brembo rear discs for a 325i to match the fronts, only to find the dish isn't deep enough to reach the 2.0i handbrake. In fact I haven't been able to find any 294mm drilled discs that would suit, it seems once you get to 294 they are all shallow dish.

Am I missing something here? It's frustrating to have gone through the whole caliper restoration procedure and sourcing everything I believe this guide points to, only to find they won't fit in the midst of the upgrade process.

Any advice would be greatly appreciated, thanks.

EDIT: READING THROUGH THE REST OF THIS THREAD IT SEEMS THIS ISSUE HAS CROPPED UP BEFORE, SO I WONDER IF THERE ARE ANY SOLUTIONS OR SHOULD I JUST FORGET THE REAR'S AND TRY AND GET SOME MONEY BACK?
 
thanatu55 said:
Has anybody performed the rear upgrade on a 2.0i E85? The fronts were no problem at all, but the rears are an issue.

I have sourced the calipers from a 325i and some 294mm drilled Brembo rear discs for a 325i to match the fronts, only to find the dish isn't deep enough to reach the 2.0i handbrake. In fact I haven't been able to find any 294mm drilled discs that would suit, it seems once you get to 294 they are all shallow dish.

Am I missing something here? It's frustrating to have gone through the whole caliper restoration procedure and sourcing everything I believe this guide points to, only to find they won't fit in the midst of the upgrade process.

Any advice would be greatly appreciated, thanks.

EDIT: READING THROUGH THE REST OF THIS THREAD IT SEEMS THIS ISSUE HAS CROPPED UP BEFORE, SO I WONDER IF THERE ARE ANY SOLUTIONS OR SHOULD I JUST FORGET THE REAR'S AND TRY AND GET SOME MONEY BACK?
Click to expand...

Hello,

Could you finally install the 320mm rear disc? Do they fit? I know there are issues with the parking brake, but I was wondering if it bolts up (leaving the parking brake useless)

Cheers
 
I assume no one has got the 320mm to fit the rear with a working handbrake?? I'm about to order the discs and pads ready to do the upgrade. Not long refurbished a full set of front and rear calipers off a 330i.
Would love to have front and rears fitted.
 
i have found out the 294mm rear discs off the E46 are not the same as the 294mm ones listed for the Z4 (real OEM part numbers). the caliper and carrier are same part number, but discs are not. can anyone explain this??
 
terryo said:
i have found out the 294mm rear discs off the E46 are not the same as the 294mm ones listed for the Z4 (real OEM part numbers). the caliper and carrier are same part number, but discs are not. can anyone explain this??
Click to expand...
i think this has been covered, i think the part numbers are differant but its only the numbers are different, the disks are the same
 
thanks Road Warrior, but my experiences in car parts tells me OE manufacturers dont change part numbers for no reason. a number change signifies a difference, usually engineering based, rather than trivial like a paint or finish alternation. i'm still searching for some sort of explanation. if you can refer me to something Road Warrior, I'd appreciate that.

the other post above re rear brakes may have identified the same problem, but its not 100% clear. Just looking thru brake catalogues i can see that the offset or height of the E46 rear disc is 75mm and this will impact on the placement of both the handbrake shoes and main friction surface.

UpDate..... i have confirmed the E46 294mm rear discs definitely will not fit. the height is different. The 294mm E85 Z4 rear disc is unique to that 3l car and not shared with any other BMW. So, the post that started off this thread, is wrong in this regard
 
All we need now is someone to start selling good quality carbon fibre replacement discs at affordable prices... one of my favourite mods on my old 3.0
 
Jembo said:
All we need now is someone to start selling good quality carbon fibre replacement discs at affordable prices... one of my favourite mods on my old 3.0
Click to expand...

No way, they'd cost thousands! I think they are produced in limited numbers for the E46 M3 (so might fit our cars), but can only be used in combination with a pricey BBK.
 
Going to source the materials and give this a go,i upgraded my TVR front brakes to Ford Cosworth as they were a straight swop.

The change in breaking was amazing and stopped on a sixpence
 
CHIMV8 said:
Going to source the materials and give this a go,i upgraded my TVR front brakes to Ford Cosworth as they were a straight swop.

The change in breaking was amazing and stopped on a sixpence
Click to expand...

The only caution I’d make is when it’s cold & wet, you may find the front may initiate the ABS on hard breaking way before the rear... though for everything else deffo worth it even with standard discs & pads
 
Jembo said:
CHIMV8 wrote: ↑Fri Jan 17, 2020 5:00 pm
Going to source the materials and give this a go,i upgraded my TVR front brakes to Ford Cosworth as they were a straight swop.

The change in breaking was amazing and stopped on a sixpence
The only caution I’d make is when it’s cold & wet, you may find the front may initiate the ABS on hard breaking way before the rear... though for everything else deffo worth it even with standard discs & pads
Click to expand...
Not sure what you mean by that? The ABS system should automatically bias between front & rear. You keep giving the (pedal) inputs and the car will sort itself out.

I've not had any problems, even with large brakes on a wet track.

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The brake bias on an E85 is fixed between front & rear, so the ABS won’t IMO sort it out.

Dry or wet in the summer I didn’t have any issue in my old 3.0, it was only during the colder months Isometines experiences this
 
Z4 e85 2005. So far, in 25000 miles... new front trailing arm bushes. New discs and pads all round. New front struts. All expected. Then.... New front left calliper, Then.... new front right calliper and new front discs again.
Not expected. I am 58. I have had a lot if cars. Have never had to replace a calliper.
WTF!
SO IS THERE A NON BMW, Z4 BRAKING SOLUTION ?
 
Oh yeah, independet dealer and AA Man say yeah... they are s**t cos the seals admit crud when you push the pistons back to fit the pads. My Saab 95 did 195,000 miles. You guessed it, never needed new Callipers.
 
Why does it need replacing?
Chances are you can just rebuild it, Big Redd do kits, give them a shout, has to be cheaper than a new caliper!
 
In fairness replacement recon calliper cleaned up with new seals as you describe, fitted, £135 ish.
The old calliper gets refurbished and goes round again. BUT....
Like I said....
WTF!
So does anyone have a reliable _roadworthy_ alternative, not necessarily BMW pattern, that can be fitted in place of this s**t calliper from BMW?
 
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