Recommended replacement interval for the part category Brake disc : 50000 km

Important!

This replacement procedure can be used for:
CITROËN Xsara Box Body / Estate 1.9 D, CITROËN Xsara Box Body / Estate 1.8 D … View more

The steps may slightly vary depending on the car design.

This video shows the replacement procedure of a similar car part on another vehicle

All the parts you need to replace – Brake Discs for Xsara Box Body / Estate and other CITROËN models

Brake disc

Brake disc for CITROËN Xsara Box Body / Estate 1.9 D Diesel (69 hp)

Simple DIY car repair steps – Replacing Brake disc on CITROËN Xsara Box Body / Estate 1.8 D

Brake disc for CITROËN Xsara Box Body / Estate 1.8 D Diesel (58 hp)

Replacement: brake discs – CITROËN XSARA Box. Tools you might need:

                        Wire brush
                      
                        WD-40 spray
                      
                        Brake cleaner 
                      
                        Copper grease 
                      
                        Combination spanner #13
                      
                        Combination spanner #15
                      
                        Torx bit T55
                      
                        Wheel impact socket #19
                      
                        Brake caliper wind back tool
                      
                        Torque wrench
                      
                        Phillips screwdriver
                      
                        Impact screwdriver
                      
                        Rubber mallet
                      
                        Tap wrench
                      
                        Crow bar
                      
                        Wheel chock

Buy tools

Replacement: brake discs – CITROËN XSARA Box. AUTODOC recommends:

Replace the brake disks on the car CITROËN XSARA Box in complete set for each axis. Regardless of the state of components. This will ensure even braking.
The replacement procedure is identical for both brake disks on the same axle.
When changing the brake discs, always replace the brake pads.
All work should be done with the engine stopped.

Replacement: brake discs – CITROËN XSARA Box. Use the following procedure:

Step 1

Open the bonnet. Unscrew the brake fluid reservoir cap.

Step 2

Secure the wheels with chocks.
Step 3

Loosen the wheel mounting bolts. Use wheel impact socket #19.
Step 4

Raise the front of the car and secure on supports.

Step 5

Unscrew the wheel bolts.

Replacement: brake discs – CITROËN XSARA Box. Tip from AUTODOC:
To avoid injury, hold up the wheel when unscrewing the bolts.
Step 6

Remove the wheel.
Step 7

Clean the brake caliper fasteners. Use a wire brush. Use WD-40 spray.
Step 8

Unscrew the brake caliper fastening. Use a combination spanner #13. Use a combination spanner #15.
Step 9

Spread the brake pads. Use a crowbar.
Step 10

Remove the brake caliper.

Replacement: brake discs – CITROËN XSARA Box. Professionals recommend:
Tie the caliper to the suspension or to the body with a wire without disconnecting from the brake hose to prevent depressurization of the brake system.Make sure that the brake caliper is not hanging on the brake hose.Don't press the brake pedal after the brake caliper has been removed. As a result, the piston can fall out from the brake cylinder, and brake fluid leakage and depressurization of the system may occur. Check the brake caliper bracket, brake caliper guide pins and boots. Clean them. Replace, if necessary.
Step 11

Remove the brake pads.
Step 12

Clean the brake caliper bracket fasteners. Use a wire brush. Use WD-40 spray.
Step 13

Unscrew the caliper bracket fastening. Use Torx T55. Use a tap wrench.
Step 14

Remove the caliper bracket.
Step 15

Clean the brake disc fasteners. Use a wire brush. Use WD-40 spray.

Step 16

Unscrew the brake disc fastening. Use a Phillips screwdriver. Use an impact screwdriver.

Step 17

Remove the brake disc. Use a rubber mallet.
Step 18

Clean the hub. Use a wire brush. Treat the contacting surface. Use copper grease.
Step 19

Install the brake disc.
Step 20

Tighten the brake disc fastening. Use a Phillips screwdriver. Use a torque wrench. Tighten it to 9 Nm torque.
Step 21

Clean the brake caliper bracket from dirt and dust. Use a wire brush. Use a brake cleaner.

AUTODOC recommends:
Replacement: brake discs – CITROËN XSARA Box. After applying the spray, wait a few minutes.
Step 22

Install the brake caliper bracket.
Step 23

Tighten the brake caliper bracket. Use Torx T55. Use a torque wrench. Tighten it to 105 Nm torque.
Step 24

Treat the brake caliper piston. Use a brake cleaner.

Replacement: brake discs – CITROËN XSARA Box. AUTODOC recommends:
After applying the spray, wait a few minutes.
Step 25

Press in the brake caliper piston. Use brake caliper wind back tool.
Step 26

Install the brake pads.
Step 27

Install the brake caliper and fix it. Use a combination spanner #13. Use a combination spanner #15. Use a torque wrench. Tighten it to 27 Nm torque.
Step 28

Treat the surface where the brake disc contacts the wheel rim. Use copper grease.
Step 29

Clean the brake disk surface. Use a brake cleaner.

AUTODOC recommends:
Replacement: brake discs – CITROËN XSARA Box. After applying the spray, wait a few minutes.
Step 30

Install the wheel.

Replacement: brake discs – CITROËN XSARA Box. Tip:
To avoid injury, hold up the wheel when screwing in the fastening bolts.
Step 31

Screw in the wheel bolts. Use wheel impact socket #19.
Step 32

Lower the car and working in a cross order, tighten the wheel bolts. Use a torque wrench. Tighten it to 100 Nm torque.
Step 33

Remove the jacks and chocks.

Replacement: brake discs – CITROËN XSARA Box. Tip from AUTODOC experts:
Without starting the engine, press the brake pedal several times until you feel significant resistance.Check the brake fluid level in the expansion tank and refill if necessary.
Step 34

Tighten the brake fluid reservoir cap. Close the hood.

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