How to Replace Front Brakes 13-20 Mini Cooper

Introduction

This tutorial provides step-by-step instructions on how to replace the front brakes and rotors on a 2013-2020 Mini Cooper. Replacing worn brakes is essential for vehicle safety and performance. Symptoms of worn brakes include squealing, grinding noises, and wheel vibrations. This guide will help you perform the replacement effectively with the right tools and techniques.

Step 1: Gather Tools and Materials

Before starting, ensure you have the following tools and materials ready:

• Flat Blade Screwdriver
• Pocket Screwdriver
• Pry Bar
• 10mm, 13mm, 17mm, and 18mm Sockets
• Brake Caliper Hanger
• Trim Tool Set
• Pliers
• 1/2 Inch Air Impact Gun
• Ratchet
• Torque Wrench
• Brake Grease
• Brake Parts Cleaner
• Copper Anti-Seize
• Gloves
• Rust Penetrant
• Safety Glasses
• Grinder
• Wire Brush

Step 2: Remove the Wheel

• Loosen four out of the five lug nuts on the wheel.
• Remove the wheel and set it aside.

Step 3: Push Back the Caliper Piston

• Use a pry bar to gently push back the caliper piston:
  • Insert the pry bar between the brake pad and caliper.
  • Apply slow, even pressure to avoid damage.

Step 4: Disconnect the Brake Pad Sensor

• Locate the brake pad sensor wire and pull it away from the caliper.
• Use a pocket screwdriver to disconnect the sensor from its connector.

Step 5: Remove the Caliper

• Locate the caliper bracket slider bolts:
  • Use a 13mm socket to loosen and remove the bolts.
• Carefully hang the caliper using a caliper hanger to avoid straining the flex hose.

Step 6: Remove Brake Pads and Caliper Bracket

• Remove the brake pads from the caliper bracket.
• Use a 17mm socket to remove the caliper bracket bolts:
  • Reinsert the bolts a few threads to hold the bracket while you work.

Step 7: Remove the Rotor

• Apply rust penetrant to the rotor area and the retaining bolt.
• Use a quarter-inch Allen head to remove the rotor bolt.
• Support the rotor with a lug stud to prevent it from falling.

Step 8: Clean and Prepare the Mounting Surface

• Clean the wheel bearing hub and rotor braking surface.
• Apply copper anti-seize to the mating surfaces.

Step 9: Install the New Rotor

• Align the new rotor with the bearing hub and secure it with the retaining bolt.
• Tighten the bolt to secure the rotor.

Step 10: Prepare the Caliper Bracket

• Remove the caliper bracket sliders and clean them.
• Inspect slider boots; replace if torn.
• Lubricate the sliders with caliper grease and reinstall them in the correct orientation.

Step 11: Install the Caliper Bracket and Brake Pads

• Attach the caliper bracket with cleaned bolts and torque them to 80 ft-lbs.
• Install the new brake pads into the bracket, ensuring they fit snugly.

Step 12: Reinstall the Caliper

• Lubricate the caliper piston and the ears of the brake pads with caliper grease.
• Carefully slide the caliper over the brake pads and align it with the sliders.
• Secure the caliper with its mounting bolts and torque them to 26 ft-lbs.

Step 13: Reconnect the Brake Pad Sensor

• Connect the brake pad sensor wire and ensure it’s secured in place.

Step 14: Reinstall the Wheel

• Position the wheel back onto the hub and start all five lug nuts by hand.
• Tighten the lug nuts in a crisscross pattern to ensure even pressure.
• Torque the lug studs to 100 ft-lbs.

Step 15: Final Checks

• Pump the brake pedal slowly to seat the new pads.
• Check the brake fluid level in the master cylinder:
  • If needed, add fluid to ensure it’s between the minimum and maximum lines.
• Reattach any covers or clips that were removed during the process.

Conclusion

You have successfully replaced the front brakes and rotors on your Mini Cooper. Regularly check your brakes for wear and replace them as needed to ensure safe driving. If you encounter any issues, consider consulting a professional mechanic. Keep your tools handy for future maintenance tasks!