I wanted to share my brake upgrade. None of this information is brand new and can be found on another forum if you want to go threw over 70 pages of info. I wanted to make a one post with all the information needed. I recommend upgrading the front and rears together to keep a balance in the braking system.
FRONT BRAKES:
Calipers: 2 used Mercedes-Benz W220 front calipers
2000-2006 S430/S500
both long and short mounting tabs work
Pads: Any brand for MB W220 front calipers
Bolts: 4 Mercedes-Benz part#1234210271
these bolts fit the thread of the MB calipers
the smaller diameter clears the MK3 mounts
Rotors: 2012 Mercedes-Benz R350 front rotors
these are 13-inch diameter
Washers: 3mm thick worth of washers x 4
Hub rings: 67.1mm to 60.1mm aluminum rings
stay away from the plastic ones
Dust shield: don't cut this! avoid sharp edges and a dangerous situation. the shield can easily be bent backwards with a hammer. if it still rubs the rotor after installation, use a large screwdriver to pry it away from the rotor.
Paint: I hit the caliper with a rotating wire brush drill attachment, then 100 grit sandpaper and brake cleaner. I used orange and black engine paints. I removed the bolts 2 at a time to paint them separately.
Brake fittings: threads match, use new copper washers, I am using a previously installed SS line kit
Wheels: 17-inch+, i have 18-inch
Piston comparison: 1x60mm MK3 piston vs 2x44mm & 2x40mm MB pistons
Installation: remove wheel, loosen brake line fitting, remove rear caliper bolts, remove caliper, remove rotor, bend dust cover, install hub ring, install rotor, install loaded caliper using new bolts, 3mm washers goes between the MK3 bracket and the MB caliper, transfer brake line fittings with new copper washers, bleed brakes, install wheel
Total cost: $374. I bought everything on Ebay except the paint.
REAR BRAKES:
Calipers: 2 used 2003-2005 Mitsubishi Evo 8 rear calipers
Pads: Any brand for Evo 8 rear calipers
Bolts: 4 M10-1.5X40mm. $1.06 each at Home Depot.
these bolts fit the thread of the Evo 8 calipers
Rotors: 2005-2007 Suburu WRX STI rear rotors
Washers: 4 2mm thick M10 washers.
Hub: STI hubs are about 58mm. Take the rotor to the machine shop and bore the hubs out to 60.2mm. $64 labor
Dust shield: don't cut this! avoid sharp edges and a dangerous situation. the shield can easily be bent backwards with a hammer. if it still rubs the rotor after installation, use a large screwdriver to pry it away from the rotor.
Paint: I hit the caliper with a rotating wire brush drill attachment, then 100 grit sandpaper and brake cleaner. I used orange engine paint.
Brake fittings: threads do not match. my understanding is that one fitting is flared and the other is inverted flared. They appear to fit at first but I had a leak. I used the stock evo banjo bolts and added a banjo fitting to my brake lines.
Wheels: 17-inch+, i have 18-inch
Piston comparison: 1x38mm MK3 piston vs 2x40mm Evo 8 pistons
Ebrake: no changes or adjustments, works 100%
Installation: remove wheel, loosen brake line fitting, remove rear caliper bolts, remove caliper, remove rotor, bend dust cover, install rotor, transfer brake line fittings, install loaded caliper using new bolts, one 2mm washer goes between the MK3 bracket and the MB caliper, bleed brakes, install wheel
Total cost: $446. I bought everything on Ebay except the paint and bolts. The bolts are from Home Depot.
FRONT PHOTOS:
REAR PHOTOS:
FRONT BRAKES:
Calipers: 2 used Mercedes-Benz W220 front calipers
2000-2006 S430/S500
both long and short mounting tabs work
Pads: Any brand for MB W220 front calipers
Bolts: 4 Mercedes-Benz part#1234210271
these bolts fit the thread of the MB calipers
the smaller diameter clears the MK3 mounts
Rotors: 2012 Mercedes-Benz R350 front rotors
these are 13-inch diameter
Washers: 3mm thick worth of washers x 4
Hub rings: 67.1mm to 60.1mm aluminum rings
stay away from the plastic ones
Dust shield: don't cut this! avoid sharp edges and a dangerous situation. the shield can easily be bent backwards with a hammer. if it still rubs the rotor after installation, use a large screwdriver to pry it away from the rotor.
Paint: I hit the caliper with a rotating wire brush drill attachment, then 100 grit sandpaper and brake cleaner. I used orange and black engine paints. I removed the bolts 2 at a time to paint them separately.
Brake fittings: threads match, use new copper washers, I am using a previously installed SS line kit
Wheels: 17-inch+, i have 18-inch
Piston comparison: 1x60mm MK3 piston vs 2x44mm & 2x40mm MB pistons
Installation: remove wheel, loosen brake line fitting, remove rear caliper bolts, remove caliper, remove rotor, bend dust cover, install hub ring, install rotor, install loaded caliper using new bolts, 3mm washers goes between the MK3 bracket and the MB caliper, transfer brake line fittings with new copper washers, bleed brakes, install wheel
Total cost: $374. I bought everything on Ebay except the paint.
REAR BRAKES:
Calipers: 2 used 2003-2005 Mitsubishi Evo 8 rear calipers
Pads: Any brand for Evo 8 rear calipers
Bolts: 4 M10-1.5X40mm. $1.06 each at Home Depot.
these bolts fit the thread of the Evo 8 calipers
Rotors: 2005-2007 Suburu WRX STI rear rotors
Washers: 4 2mm thick M10 washers.
Hub: STI hubs are about 58mm. Take the rotor to the machine shop and bore the hubs out to 60.2mm. $64 labor
Dust shield: don't cut this! avoid sharp edges and a dangerous situation. the shield can easily be bent backwards with a hammer. if it still rubs the rotor after installation, use a large screwdriver to pry it away from the rotor.
Paint: I hit the caliper with a rotating wire brush drill attachment, then 100 grit sandpaper and brake cleaner. I used orange engine paint.
Brake fittings: threads do not match. my understanding is that one fitting is flared and the other is inverted flared. They appear to fit at first but I had a leak. I used the stock evo banjo bolts and added a banjo fitting to my brake lines.
Wheels: 17-inch+, i have 18-inch
Piston comparison: 1x38mm MK3 piston vs 2x40mm Evo 8 pistons
Ebrake: no changes or adjustments, works 100%
Installation: remove wheel, loosen brake line fitting, remove rear caliper bolts, remove caliper, remove rotor, bend dust cover, install rotor, transfer brake line fittings, install loaded caliper using new bolts, one 2mm washer goes between the MK3 bracket and the MB caliper, bleed brakes, install wheel
Total cost: $446. I bought everything on Ebay except the paint and bolts. The bolts are from Home Depot.
FRONT PHOTOS:
REAR PHOTOS: