Hi all,

Installing new rotors for the first time and I've come to some difficulty in the process. I've removed the rotors using the tensile bolt and it came off fine (was tough as nails to just pull off). Then when I had removed the rotor, it all looked very strange...

I don't know what the part is called but i can describe this as the part that sits inside the top hat of the rotor which has small spring tension when you rotate it. Anyways, there's pins in the left hand side and right hand side followed with a spring and a cap to hold the tension of the spring. The left side pin/spring had collapsed when I'd taken the rotor off. I put it all back together but having difficulty in putting in new rotor on. It seems the new rotor doesn't just slide on and doesn't fit.

What I mean by it not fitting is, is that the rotor fits is sliding on about 3/5 of the bolt holes, but not fitting on the other 2, as if its being obstructed by something

I'm sure I'm just doing something procedurally wrong here, but I can't seem to dig up any info n my situation.

Talking about the rear discs?
If so, you should back off the brake shoe before pulling the rotor. If you use a bolt to free up the rotor, it is only the initial breakaway that it should do, the rotor should just slide off, unless it is catching on the brake. Forcing it off then damages things.
Have a look at the manual to see how it all fits together, or pull the other side off correctly to see how it is all arranged.

Then again you are talking about a 380 so I may just be talking out my Ar#se. Sure Mal will sort me out again, in that case. lol

Yeah sorry I forgot to mention that it is the rears I'm doing. I've gone over the work shop manual, but it doesn't go past changing the tyre unfortunately. Madmax, you've identified the part I'm talking about, it is indeed the brake shoe. When taking off the rotor, I just used two bolts to evenly take off the rotor. There wasn't any forcing action involved.

So this brake shoe is giving me a hard time in fitting the new rotor, any suggestions or ideas as to why?

You need to back off the adjuster so the shoe contracts before you pull the rotor off. The new rotors should just slide on without any force needed. When it is on, readjust the shoe.

http://i881.photobucket.com/albums/ac19/rons105/brakerear_zps5700fdeb.jpg

This is out of the third gen manual.
If the old disc pulled on the brake shoe at all during disc removal, the clip near the number 7 can be bent out of shape. Assuming the 380 is the same, have a look at that.
(From your description the 380 uses a pin, spring and hat setup to retain the shoe, just make sure it is sitting correctly.)
The adjuster is at the top, not shown, in the gap of the horseshoe shaped brake shoe. Use a screwdriver to wind back the adjuster, from either side. A rubber dust cover needs to come off the backing plate when you release or adjust the shoe with the disc on.

The shoe(s) can be moved up or down so it will fit inside the rotor, sounds like something moved when you pulled the rotor off.
I've only got the 380 manual as an .iso, so I can't check the exact setup.

You did not back off the handbrake when you removed the rotors, the parts you have broken are to do with the handbrake, is totally different to the third gen so the above diagram is useless

You will need to get a diagram from a 380 manual or compare to the other side if that has not fallen apart as well

Hey guys, I figured it out. I released the handbrake after all this and the shoe was able to clip back into position if that makes sense. Rotor fit right back on after.

Hey guys, I figured it out. I released the handbrake after all this and the shoe was able to clip back into position if that makes sense. Rotor fit right back on after.

A classic first timer mistake. lol. Make sure you adjust the handbrake when it is all back together.

Mal, basic principles applies to any rear disc/handbrake shoe setup, ie:
Back off the shoes.
Don't force the disc off.
Clean, check handbrake components.
Assemble, adjust handbrake shoes.

Will look at the 380 manual to see how it differs, thanks for the heads up.

Yep! Glad I got all you whizzes to help me out..having done my pads and rotors now, picked up some great experience that will now cost me less in the long run! An easy DIY job with the appropriate research.