Do-it-yourself rear disc brakes on a VAZ 2109 with a handbrake: instructions

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Many people want to install rear disc brakes on their VAZ 2109. But how rational is this decision?

Making such changes to the design of the brake system is prohibited. Such work is carried out entirely at your own responsibility.

Work kit

Benefits of rear disc brakes

Rear disc brakes on the VAZ-2109 are in demand in the automotive spare parts market for a number of obvious reasons:

with them the braking distance of the car is significantly reduced;
ZDTs greatly simplify pad maintenance;
the reliability of the brakes is greatly increased, which improves the safety indicator;
Braking power is applied evenly across all wheels;
due to the special method of thermal dissipation, overheating of the heat exchanger is eliminated;
unsprung mass is reduced;
in the winter season you don’t have to deal with such a problem as frozen brakes after washing;
From an aesthetic point of view, the wheels look better.

Lada 2109 by GARAGE 32 › Logbook › installation of an air defense valve on a VAZ 2109

TankestadoR last online more than a month ago

In the morning, with a sore head, I trudged into the garage with the thought (what a banana the handbrake doesn’t hold), but oh well, the store-garage route has not been canceled =) I pulled it into the garage from the store, started looking, pulled it - it doesn’t hold (the thought flew through my mind “ what the heck?), climbed further along the chain of events. After the 2nd bottle of beer, a thought clicked in my brain (100% will be good for the pads, because the brakes were very light), I threw off the wheel at the speed of sound, unscrewed the guides and angrily swore at the fact that I didn’t buy a puller to remove the drum, well I had to do occupational therapy with a sledgehammer)) 2 hours of torment and long live horror)) the work on the drums was simply unearthly depth (3mm collar) with the idea of installing new drums, a set of pads and a brake cylinder, I finished it right away! It makes sense to invest so much money when half of the spare parts from 21099 are lying in the garage (inherited from my father-in-law) I rummaged around and found the required front calipers assembled) fermented in the WD for an hour and started unwinding, untwisted, went through the bracket and painted it in the color of the front ones (light green) so as not to be rusty)) the brake discs were cockroached by a turner, to be machined for the inner landing diameter of the hub (59.8 mm), I sharpened them and went online to find what I was looking for, namely the adapter faceplates for disc brakes) more than one was killed evening in search, but! long live the miracle! what I was looking for turned out to be right under my nose (3 stops on the trolleybus) I came running, all washed up with a gas mask to the advantage, to that same treasured store with spare parts aaaand... then the bird “OBLOMINGO” (maybe you know this one) visited me, the seller Pavel Sh. says that You can order such faceplates from them, but the delivery time is 2-4 weeks, what should I do? I order faceplates, but without despair I put my skis in the treasured garage and diligently begin to twist the hubs, a long, tedious process, but with beer and music it’s still more fun) after I finally twisted the hubs, a small question arose, namely how should I unscrew 2 bolt for fastening the support disk (on which the pads and cylinder were attached) on the bolts, where I later found out there should have been a cross for a screwdriver, which I did not find, but instead I saw something that most likely should have resembled it (thanks to the previous owner! ) well, “the grinder is the best friend - said the cutting disc to the support”, with the help of simple movements, he ground the head of the bolts to an unrecognizable shape and with the calmest soul knocked the hub out of the support disc, then there was a lot of WD, mat and pliers (obscene language) they unscrewed, were happy, got drunk with joy) several days passed (I won’t name the number, because I’m afraid to lie) my long-awaited transition faceplates arrived, flying from the store to the garage at the speed of sound, bypassing the store (which I later regretted), I began installing the faceplates and... as always, maliciously I cursed and realized that I forgot to buy the bolts that were written about in the installation guide, what should I do? I had to go to the store and look for bolts, which ended up taking 2 days (since a bolt m10x1.25x30 is a rare thing), I found and took the last ones from a guy in the market for 20 rubles apiece (12 in total), bought 4 tensioner pulley washers Timing belt, thinking I’ll do one side first, then I’ll move to the other, if necessary, I’ll buy more (luckily there are enough of them everywhere), crawling into the garage I install it, after straightening the rear beam with a sledgehammer on one side of the hub, then I put on the brake disc and throw on the bracket for fitting and O miracle! my instincts did not let me down, I put 1 tensioner washer under the bracket bolt and, rummaging through the supplies, another one 2mm thick, screw it on and voila! The ZDT is installed, the only thing left is to screw on the brake tubes, realizing that they are too long, I go to the store and buy 2 smaller tubes (in my case from the sorcerer to the beam from the 10 VAZ model), I bleed the brakes with a friend and put the faceplate on the second side in in a leisurely manner. Of course you ask, what about the handbrake? My answer to this question is simple, you don’t have it in this configuration, therefore you need to install a hydraulic one, but that’s a completely different story)))) To use the information material on installation, I went to the Internet, THANK YOU to the Author for describing it in such detail installation of the HDT, low bow to you) www.vazclub.com/vaz/2108-…ad-diskovih-tormozov.html

Price tag: 2,000 ₽

Disadvantages of TRT

Naturally, where there are advantages, there are always several disadvantages:

First of all, it is worth noting the price, which is significantly higher than that of drum brakes.
The need for high-quality adjustment, which may cause a call to the service center.
Poor-quality installation leads to the fact that the safety of the car is reduced - the car skids.
In the case of the VAZ-2109, like any other VAZ model, the installation of an anti-aircraft protection device is not a certified event and may result in a fine from the traffic police.
If you get into an accident, most likely, the expert will find you at fault, since the improvements to your car will be illegal.
The lack of high-quality tuning can lead to the fact that the rear wheels can brake much better than the front wheels, which is fraught with serious consequences and emergency situations.

In other words, self-installation of the HCD on the VAZ-2109 is recommended only if you are confident in your capabilities. Otherwise, it is recommended to contact a service center. Despite the fact that the safety of your car with such tuning will increase, you may encounter problems with the traffic police, since such improvements are not legal.

WHAT PROBLEMS CAN APPEAR AFTER CHANGING DRUM BRAKES

VAZ 2109 rear disc brake

Of course, the VAZ plant does not officially install rear disc brakes on its cars, but despite this fact, the instructions provide a section on replacing brake drums with disc devices. Let's pay more attention to the shortcomings of installing the HCD on VAZ 2109 cars. So:

High-quality brakes are the key to safety. They are not installed just for beauty; they are precisely balanced mechanisms developed by experienced engineers. It’s not enough to just buy and deliver a product; it needs to be properly adjusted and tested. All this work can be done either at a service station or independently, following certain instructions. In the worst case, braking will be uneven, the car will skid when braking, the discs may overheat and complete or partial failure. In addition, you can hear an unpleasant creak.
It is not always practical to install an HTD on VAZ cars. Perhaps the money spent produces the desired results, but along with the purchased HRT, new problems arise.
Troubles associated with maintenance. Even though HBRs are much more efficient than drum brakes, replacing them is perceived as an illegal change.

VAZ 2109 how to make rear disc brakes

Problems on the road with traffic police. Often on the road people don’t find much fault with the rear brakes, but if this does happen, you’ll have to come up with a convincing explanation.
Troubles with the handbrake of a VAZ. When changing brakes, you will need to think about the handbrake. You can consider two options: installing a cable handbrake or using a hydraulic handbrake. In the second case, it becomes possible to brake on any plane, but it is not recommended to use it for parking, since it weakens over time. Some drivers do not pay attention to the handbrake at all and pass the technical inspection without any hindrance.
In an accident, a car with rear disc brakes will most likely be the culprit, since design changes have been made that are not required by law.

VAZ 2109 rear disc brakes

Setting up the braking system. Upon completion of the installation of this mechanism on the VAZ 2109, in any case, you cannot do without adjusting the sorcerer. In the worst case, the rear wheels will brake more than the front wheels. An incorrectly adjusted sorcerer can cause skidding, squeaking and overheating of discs.

Note! In certain cases, the problem of excessive braking of the rear mechanisms cannot always be solved, so it is necessary to grind down up to 25 or 50 percent of the pads, which reduces the contact area.

Necessary materials

If you decide to install the HTD yourself, then you will need the following materials:

Directly disc brakes, machined under the hub by 0.6 cm. The diameter of the disk should be 24 cm. Please note that it is not necessary to grind the disk itself. If you want to leave it unchanged, then you need to groove the hub.
Front calipers and hoses.
Faceplates necessary for attaching calipers. You will have to tinker with this part, since it is quite unusual and requires separate manufacturing to the exact dimensions.
High quality pads that fit true to size.
12 bolts M10 × 1.25 with groovers.
8 spacers. You can use timing belt tensioner roller washers for the VAZ-2108.

When you have acquired all the necessary materials, it’s time to proceed directly to the replacement. The procedure is performed in several stages.

Installation process

If any difficulties arise during dismantling, then it is worth looking into the VAZ 2114 service manual, there is a detailed description of the removal and installation of all mechanisms. And now to work:

The cable tension must be loosened and the rear pads must be brought together. After this, you can use the 12th key to remove the guide pins. The seat must be thoroughly cleaned with a metal brush, and then the drum must be knocked down. It is not recommended to use a metal tool for these purposes, as it can damage the seat. The best solution would be a rubber hammer;

Important point! Sometimes one pin hole in a mechanism is smaller than the other. It is not recommended to adjust this size yourself. The best solution would be to go to a workshop where the diameter can be quickly adjusted.

The caliper can be located in front or behind the wheel axle. This should not affect the operation of the mechanism in any way, but usually owners of the VAZ 2114 prefer to install it on the rear axles, since symmetry will have a positive effect on braking. The next step is to join the faceplate and hub. You should check that the centering has been carried out thoroughly. If there are defects, the docking must be repeated;

Stage 1. Removal of the PTA

First of all, you need to remove the wheel. After this, you need to loosen the handbrake cable and bring the pads together. The guide pins are unscrewed using a 12mm wrench.

If the car is old or the brakes have not been changed for a long time, it is recommended to treat the seats with a wire brush, and also lubricate all running surfaces with WD40. This will help you remove the brake drum without much effort.

Please note that even if the drum is tight, you need to remove it gradually, gently tapping it with a hammer along the entire circumference. If you do not want to damage the part, then use a hammer with a rubber tip or a rubber gasket.

Next, remove the tension spring and guides by prying them off with a screwdriver. After this, the brake pad needs to be lifted up, the spacer bar removed and the pad and tension spring removed.

To remove the second block, you need to remove the handbrake lever from the cable. The bolts that secure the hub to the beam should be treated with WD 40 and unscrewed with a split or regular 17 wrench.

At the last stage, the brake tube of the hub is dismantled. After this, you can begin installing the HCD.

Replacement

Since you can no longer be stopped and you want to equip the rear wheels of your VAZ 2109 with disc brakes, first prepare a set of necessary components that will be useful during the replacement process.

Calipers. Take simple front calipers from a VAZ 2109;
Hoses. Use front brake hoses as standard iron hoses will not reach into place;
Pads. Any high-quality pads of the required size will do;
Bolts, washers-grower. Requires M10x1.25 bolts 30 millimeters long. A total of 12 pieces and always with growers;
Distance washers. Take the timing belt tensioner roller washers, which are used for the VAZ 2108. You need 8 of these pieces;
Faceplate or caliper mounting plate. Need 2 pieces. Moreover, this part is non-standard; it will have to be made as accurately as possible using a coordinate machine;
Disks. Front discs with a diameter of 240 mm are suitable. First sharpen them so that the hub seats coincide by 60 millimeters. You can machine the hub itself, not the brake disc. The choice is yours.

To achieve a high-quality result when installing disk mechanisms, you first need to ensure proper dismantling of the elements of the braking system.

Dismantling

Let's start the procedure. It is not the easiest, but it is quite possible to do it yourself.

Remove the wheel.
Release the tension on the handbrake cable and close the rear pads.
Using a 12mm wrench, unscrew a pair of guide pins.
Using a hammer, carefully knock down the brake drum. Before doing this, it is better to clean the seats with a wire brush, and also treat the surfaces with WD40.
Apply gentle blows with a rubber mallet or use a wooden block. You should knock along the entire circumference of the brake drum. In some cases it comes off quite hard, but be patient.
Using a screwdriver, pry up the lower tension spring TK and remove it. Using the same spring, you can remove the small springs (guides) that press the pads to the boot. This is the brake cylinder shield.
Remove the springs, then grab the bottom of the brake pad and lift it up.
Place the upper part against the brake cylinder and remove the spacer bar.
Remove the shoe from the brake cylinder and remove the upper tension spring TK.
Remove the handbrake lever from the handbrake cable and remove the second brake lever.
Remove the bolts that secure the hub to the beam. Arm yourself with a split wrench or a regular open-end wrench 17 and a wrench to increase the leverage. Treat the bolts with WD40 and remove them.
Proceed carefully, no sudden movements. Otherwise, you will simply lick off the edges of the fasteners.
Before knocking down the hub, remove the brake pipe. To do this you need a split wrench. Having torn off the fastening, bend the tube slightly to the side and seal it with a cap, which must first be removed from the cylinder bleeder fitting. This will prevent brake fluid from leaking.
The hub is held in the seat of the beam, and it is there from the factory. That's why she probably got attached to it. The blows will have to be delivered accurately and powerfully. Hit the support disk from the inside, alternating strikes from above and below.
If you ruin the platter, no big deal. It's going to landfill anyway.
When the hub begins to gradually separate from the beam, apply less strong blows. Knock off the hub completely.

Replacement procedure

Installation of HTD

Now comes the most crucial moment - installing disc brakes on the rear wheels of your VAZ 2109.

Decide exactly how the caliper will be mounted. This can be done from behind or in front of the axle. Please note that this does not affect efficiency, so there is no need to think too much. To make it more symmetrical, we choose the rear location.
Join the hub and faceplate into a single unit. Make sure the holes line up. If there are any inaccuracies, use gentle hammer blows to center the position. It is very important.
Straighten the corners of the beam on which the caliper will eventually be able to rest. This can be done with a regular hammer. The processing of one or another corner depends on which side you chose for installation.
Install the hub. Please note that you do not need to use an engraver for the upper left hub fixing bolt. Otherwise, you will have to work with a grinder, grinding off the fastener head. Without doing this, the caliper bracket will simply rest against the gromver.
Place the purchased disc brake on the hub.
Install a bracket on the faceplate, and place washers between the elements at the joints. This will give you the necessary clearances.
In some cases, washers do not correspond to the required dimensions, so it is better to choose them specifically for your car.
The connection between the faceplate and the bracket is tightened with an applied force of 3-4 Nm.
Install the pads, connect the hose to the caliper, and then connect the tube to the hose. It is important not to do the opposite here.
Seal the brake line and pressurize the system by pressing the brake pedal. Make sure the system is tight and there are no leaks.
If everything works well, you can install the brake discs on the second rear wheel in the same way.

ZDT

After completing the assembly of the new brake system on the rear wheels, be sure to bleed the brakes. You cannot go on the roads without this.

It would be a good idea to visit a trusted car service center, where experienced specialists will analyze the quality of replacing drums with discs and make sure that the settings are correct. It would be nice to have friends here who won’t deceive you.

Adjusting the pressure regulator on the rear axle (sorcerer)

If you have a rear brake pressure regulator installed (a sorcerer in common parlance), then you need to reduce the force. I will show you how to do this in the figure:

We loosen the fastening of the lever number 2, and adjust the regulator number 1 towards the beam number 3.

To be honest, I didn’t do this and have no complaints.

Source: lada-na-remont.ru

Removing the protrusion

To ensure uniform metal removal, the hub must be rotated. This operation must be performed extremely carefully, and not remove excess, because the brake disc must be pressed tightly enough:

When choosing one of three types of discs for a VAZ, do not forget that it should be several inches smaller than on the front brakes. The disc is installed on the hub and secured with bolts.
After this, the caliper of the required size is fixed, the hose is connected to the brake pipe.
Next you need to bleed the brakes.