Change rear brake discs and pads Alfa Romeo 159

Wedge the front wheel on the side opposite the one you are going to work on with 2 shims. One at the front and one at the rear.

Shift into first gear and release the handbrake.

Loosen the rear wheel screws on the side you are going to work on using a cross or suitable wrench. Diameter 17

Raise the rear of the vehicle at the jacking point. Then position the jack stand.

Never work on the vehicle using only the jack.

Here I used a trolley jack but you can also use the vehicle's own.

Completely loosen the wheel nuts and then remove the wheel.

Securing the vehicle: removing and refitting the wheel

Remove the pin holding the hose using pliers and set it aside so that it does not get lost.

Remove the hose from its support

Using a 15 flat wrench and another wrench or socket (here a ratchet with socket) unscrew the 2 screws holding the caliper.

You have to hold the 15 flat key so that the axle does not turn and unscrew with the 13 key

Remove the caliper using the screwdriver, levering once at the top and once at the bottom.

In principle, there is no need to force it.

During work, hold the stirrup with a cable or wire. Here I used a piece of an old coat hanger that I cut with wire cutters.

Check the condition of the dust covers. If they are pierced or damaged, they will need to be replaced.

Open the jar containing the brake fluid under the hood

During the push back of the brake piston the level will rise in the reservoir. It is necessary to check regularly so that the latter does not overflow. If necessary use a syringe or a bulb to remove the excess.

Dust the dust cover

Push the piston back using the piston pusher which must turn and push the piston simultaneously.

The piston must be turned clockwise during the push (same direction on both sides of the vehicle)

Once the piston is pushed back the notches of the piston must be positioned in the same position as before pushing back. See Photo 3

Remove the old pads by tilting them

Remove the pad retaining springs and set them aside

Unscrew the 2 screws that hold the brake caliper support. This is not easy because they are mounted with thread lock and their end located under the disc is rusty

Use an E12 key or socket

A tube as an extension is essential to have the force necessary for loosening.

Be careful that the key does not slip off the screw while unscrewing. You risk damaging it and having very big problems disassembling it later.

Unscrew the screw that holds the disc using a 5mm Allen key

If the disc does not come out, you will have to tap all around with a mallet.

If the disc is really a problem. You can also use penetrating oil to separate the disc from the hub. Spray all the holes in the disc as well as the back of the disc on the part in contact with the disc/hub.

Clean the hub using a wire brush and/or sandpaper

Apply a very thin layer of grease to the hub to simplify any future disassembly.

Put very, very little grease on the hub so that it does not end up on the disc.

Clean the caliper bracket with a wire brush, especially the parts in contact with the brake pad springs.

Be very careful not to damage the dust covers!

Clean the pad springs. Spray them with penetrating oil and then rub with a cloth. Remove imperfections with 600 grit sandpaper. The surface in contact with the pads must be perfectly smooth!

Also clean the metal protection of the disc using brake cleaner/degreaser

Fit the new disc after degreasing it with the brake degreaser spray.

Screw in the screw holding the disc to the hub. Normally new screws are supplied with the discs

Clean the threads of the caliper bracket screws with a wire brush (remove rust on the tip)

Apply threadlock to the caliper bracket screws. Then screw the caliper bracket on tightly.

Do not use too much thread lock or you will have problems during the next disassembly.

Reassemble the pad springs

Place the new pads by inserting them at an angle and pushing very lightly.

Replace the caliper then screw it in with the 2 new screws supplied with the pads.

No need to put thread lock here. As you can see the new screws are already coated with blue glue on the end.

To screw the caliper back in, proceed as for disassembly. Hold with the 15 mm flat spanner and screw with the 13 mm spanner.

Fit the hose onto its support bracket and replace the pin.

Reassemble the wheel, tighten the nuts following the order in photo 2

Place the vehicle back on the ground and then tighten the wheel nuts securely.

Proceed in the same way to make the second side.

Don't forget the wedges under the front wheel

Once both sides are finished, pump the brake pedal several times until it becomes hard. Check the brake fluid level and close the reservoir.

Also remember to check that the handbrake is working properly. If necessary, you can adjust it by acting on the nut located at the handbrake lever in the passenger compartment.

You will need to be very gentle with the brakes to ensure good running-in of the pads for the first 200 to 300 km. Avoid any potential overheating of the brakes at the risk of "glazing" the pads and having to replace them again.

Be careful, the first braking can be very bad! Stay careful