DIY: 5 Lug Swap Conversion - 02/03 ep with 02/03 DC5 Type S Parts

this is generation three. this DIY has been tweeked with minor changes so do your own work at your own risk. this is a suggestion, not step for step directions. Make sure you research your parts and compatibility to your car, suspension, rims, etc. Makre SURE the parts you plan on putting on - WORK - before putting them on your car. this is your BRAKING system... don't half ass it. With that said - HAVE A BLAST! And have airtools... LOL


Parts Needed for this swap:

* Type - S 5 lug full swap. (if you get 02-03 type s setup for the same model year ep, then you can use
your ep brake lines & lca's
* Type S Axles 02-03 for 02-03 ep's
* axle/ball joint grease
* brake fluid
* PB Blaster
* Type S ball joint boots (2)


Tools Needed/Suggested:

Sockets:

14, 17, 22, 1.25 or 32, 36

Tools:

socket extension
Flat head screwdriver
Breaker Bar
Pickle Fork or ball joint puller
Tie Rod Puller
hammer
PB Blaster - your best friend


passenger front side:

1. after removing wheel, remove 2 bolts holding the suspension to the brake.




2. Loosen brake line bolt - remove brake lines






3. 32 mm (1.25) to remove center axle nut, use flathead & hammer to "open" the bind in axle nut.
this will allow you to take the nut off the axle bolt.







4. use extension & 10 mm and remove ABS sensor on rear of rotor. (black plastic piece).




5. here is where a ball joint puller comes in handy, if you dont have one, use a pickle fork & hammer
LCA to loosen ball joint. use jack to raise brake/rotor assembly & continuous hammer on LCA. once
ball joint lets go, you then remove shock bolts








6. pull off rotor assembly from the car




7. remove axle




repeat steps for drivers side.


Ball Joint Boots

use hammer & flathead to pop out (ring holder in at base of boot)





Installing New Axles


install type s axles - but grease them before installing.

install new ball joint boot & put some ball joint grease in the boot.





install type s rotor onto type s axle




install strut bolts




Ep ABS sensors can be reused on type s swap but ABS line MUST be taken off clamp for ABS to
allow more slack in the line. clamp should be bent closed and bent back out of the way of the line.
Washers will also be needed to pull it away from the ABS and keep it from being ground down!


reinstall 36mm axle lug with socket - redo the "groove" to lock the nut in place.





DO NOT PUT ABS LINE INTO CLAMP, SEE INSTRUCTIONS ABOVE.


REAR BRAKES:

Tooles Suggested:

3/4 or 19mm, 12mm, 14 , 10, swivel head socket


after removing rear wheel, remove brake line on rear brake


remove e-brake cable with flathead, to remove retainer clip, tap out E-brake cable.




take off e-brake cable bracket.



SRS sensor - remove - 10mm socket & flathead.




17mm & 14mm - remove strut bolts




grease rear trailing arm bushings


INSTALLING TYPE S BRAKES


install type s rotors on rear & place bolts - tighten

replace ebrake cable back on to type s rotors - 12mm.

reuse retaining bracket of ABS onto type s to reinstall the line.

reinstall brake line - 14mm


Bleed your brake lines thoroughly!!! all 4!!!
make sure your resivoir tank stays within limits also. you will need a friend to pump the brakes
while you are bleeding each line.

once all lines are free of any bubbles, tighten down and level off resivior tank in engine bay.


enjoy your new 5 lug swap!