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P.A.W. Maestro/Montego Brake Conversion

General Information

This conversion, properly carried out, provides a better braking system for the higher performance Maestro/Montego cars.

It is important that all steps are followed and understood before work commences.

A fitting service can be provided if required, contact the factory for details.

After installation, drive the car gently to bed in the brakes, checking for vibration or judder on braking that may indicate the kit has been fitted incorrectly.

After one week of bedding the brakes in, make a visual check on the installation and check all bolts for tightness.

At six-monthly services, the above check should be made as routine.

TAKE NO CHANCES WITH YOUR BRAKES - A LIFE IS AT STAKE.

Fitting Sequence

  1. Remove the brake caliper and disc in accordance with the manufacturers handbook. Support the caliper taking care not to strain the flexible brake hose.
  2. Remove the bottom bolt securing the suspension strut to the hub carrier.
  3. Remove the bolt from the bottom of the hub carrier that secures the bottom ball joint.
  4. Bend the stone shield retaining ears so that they fit on the outside of the caliper mounting lugs. A small piece of the shield may need trimming to clear the caliper when mounted.
    NOTE Do not leave the ears in their original position as the caliper will not line up with the new disc.
  5. Attach the angle plate to the inside of the original caliper mounting lugs, securing the stone shield with the 12 mm cap screws and lock washers. It is also recommended that a thread locking compound is used.
  6. Using the 12 mm short spacer and 12 mm long cap screw, insert the cap screw through the bottom suspension strut, securing the top of the caliper bracket to the spacer with the 12 mm lock nut and washer.
  7. Using the 10 mm cap screw and spacer secure the bottom ball joint to the caliper bracket and secure the 10 mm nut and lock washer. It is possible that due to the type of suspension strut that is fitted to your car, the spacer may not be a good fit, either too big (file or skim to fit) or too small (contact the factory for replacement with the necessary dimensions).
  8. Fit the new disc with the locating ring (chamfered edge to the inside). Secure with the original 6 mm countersunk screws. Check for run out in the usual way to Rover specifications.
  9. Using a G clamp, push the caliper piston into the caliper to aid fitting of the pads later.
    Now fit the caliper to the angled bracket with the flat sided spacers. Using the 12 mm cap screws with 1 plain washer and 1 lock washer. This is important so that the cap screw does not protrude towards the disc. Secure with locking compound.
  10. Fit the pads in the usual way, in accordance with manufacturers data.
  11. Before re-fitting the wheel it may be necessary to angle grind / file the top and bottom of the caliper anchor plate (0.040 - 1 mm) to clear the inside of the wheel, depending on the road wheel used.
  12. When both sides have been completed, depress the brake pedal several times to settle the brake piston on the pads. Refer to 'General Information' with regard to servicing and initial bedding in of the brake conversion.