Table of Contents
Upgrading your Mazda RX-8 with the Cosworth Big Brake Kit can significantly enhance your vehicle’s braking performance. This step-by-step guide will walk you through the installation process, ensuring you have all the information needed for a successful upgrade.
Tools and Materials Required
- Cosworth Big Brake Kit
- Socket wrench set
- Torque wrench
- Brake cleaner
- Jack and jack stands
- Brake fluid
- Rubber gloves
- Safety goggles
Preparation Steps
Before starting the installation, ensure that you have all the necessary tools and materials at hand. It is also important to work in a well-ventilated area and wear safety gear to protect yourself during the process.
1. Safety First
Put on your safety goggles and rubber gloves. Ensure that your work area is clear of any obstructions.
2. Lift the Vehicle
Using the jack, lift the front of the Mazda RX-8 and secure it with jack stands. Make sure the vehicle is stable before proceeding.
Removing the Old Brake Components
To install the Cosworth Big Brake Kit, you must first remove the existing brake components. Follow these steps carefully.
1. Remove the Wheel
Using the socket wrench, loosen the lug nuts on the wheel. Once loose, remove the wheel and set it aside.
2. Disconnect the Brake Line
Carefully disconnect the brake line from the caliper. Be prepared for some brake fluid to leak out, and have a container ready to catch any spills.
3. Remove the Caliper
Remove the bolts securing the brake caliper to the bracket using a socket wrench. Once removed, carefully take off the caliper and hang it securely to avoid straining the brake line.
4. Remove the Brake Rotor
Next, remove the brake rotor by unscrewing any retaining screws. If the rotor is stuck, gently tap it with a rubber mallet to loosen it.
Installing the Cosworth Big Brake Kit
Now that the old components are removed, you can proceed with the installation of the Cosworth Big Brake Kit.
1. Install the New Brake Rotor
Position the new brake rotor onto the hub and secure it with the retaining screws. Ensure it is seated properly.
2. Install the New Caliper
Attach the new caliper to the bracket and secure it with the supplied bolts. Make sure to follow the torque specifications provided in the kit instructions.
3. Connect the Brake Line
Reconnect the brake line to the new caliper. Ensure that the connection is tight and free of leaks.
4. Repeat for the Other Side
Repeat the above steps for the other side of the vehicle to ensure balanced braking performance.
Final Steps
Once both sides have been installed, it’s time to finalize the installation process.
1. Bleed the Brakes
Using the brake fluid, bleed the brakes to remove any air from the system. Follow the recommended procedure for your vehicle.
2. Reinstall the Wheel
Place the wheel back onto the hub and hand-tighten the lug nuts. Once all are in place, lower the vehicle and then torque the lug nuts to the specified settings.
3. Test the Brakes
Before driving, pump the brakes a few times to ensure they are functioning properly. Check for any leaks and ensure everything is secure.
Conclusion
Installing the Cosworth Big Brake Kit on your Mazda RX-8 can greatly enhance your braking capabilities. By following this step-by-step guide, you can ensure a successful installation and enjoy improved performance on the road.