Installation Guide (v1.3) for Rear Disc Brake Mounting Kit Using Renault Megane II Calipers (All Versions)
for Suzuki Grand Vitara I (1998–2005)

This guide is not detailed and installation should be carried out by a qualified workshop specializing in 4x4 vehicle modifications.

1. Completely remove the original drum brakes
   Remove the drums, brake shoes (disconnect the handbrake cables), wheel cylinders, both original metal brake lines, rear drive shafts.
   
   


2. Install caliper mounting flanges and new dust shields:
   
   • IMPORTANT! Place washers between the caliper mounting flange and the axle housing – 1 pcs per bolt
   
   • install new dust shields
   
   • remove all 4 studs from both rear drive shafts, then install the drive shafts into the axle housing and tighten everything together
   


3. Install brake discs directly onto the rear drive shafts (in most GVI models, the center bore in the discs must be machined from 107 mm to 108.5 mm – DISCS FROM US ARE ALREADY MACHINED to 108.5 mm).


4. Rear Megane II calipers:
   
   • before installation, swap handbrake cable mounts from the left caliper to the right caliper and drill the mounts from 12 mm to 12.5 mm
   
   
   
   • between the calipers and mounting flanges, under each of the 4 bolts, use 1 pcs of 12 washer and 5 pcs of thick 12 washers – total spacing 31.3 mm, but in some versions a different number of washers may be required
   


5. Brake line installation
   • connect the original flexible hose in the center of the axle to a new 200 mm copper line, then to a T-piece mounted to the axle
   
   • from the T-piece run copper lines to the left and right wheels, then connect them to the calipers using new flexible hoses
   
   
   


6. Handbrake cable installation:
   • install 6 pcs of 12 mm washers under the sheath of the left cable and 6 pcs for the right cable
   
   • cut off the original cable ends and remove the springs
   • install screw-on cable ends using a 10 mm wrench on both handbrake cables (marked "K" in the photo)
   


7. IMPORTANT!
   • During brake system bleeding, the calipers must be removed and positioned at an angle corresponding to their original factory position in Renault Megane (as shown in the image below).
     
     In this position, the bleeder screw should be facing sideways. During bleeding, a suitable spacer must be placed between the brake pads (in place of the brake disc) to prevent them from compressing and the piston from being pushed out.