I am the original owner of the 2004 G35 with 110k on clock that served me faithfully for all these years. It has been a good car except for brakes and suspension rattles! I simply can not phantom what Nissan engineers were thinking when they installed Altima sized rotor 296mm on the front end of the 3500 lb sport sedan. After 5 sets of front rotors I had enough! The BBU (bigger brake upgrade) had the following goals:
Keep it low cost - this is my daily driver
Parts sourcing - OEM or common after market
Must use OE rims and tires (17")
No more warped rotors after 15k and longer service interval between brake jobs.

Calipers (front and rear) were sourced from JY and EBAY. Front calipers came from 06 G35 AWD and were powder coated, rear set came from 06 M35 which shares the same brake system parts with G35

BOM (Bill of material)
FRONT
Calipers (06 G35)
41001-CM40A Right Front
41011-CM40A Left Front
Rotor
D0206-ZA500 Right Front
D0206-ZA500 Left Front
Centric #: 12042080
Height: 49.2 mm
Diameter: 320 mm
Pitch Circle Diameter: 114.3 mm
Brake Disc Thickness: 28.1 mm
Minimum Thickness: 26.0 mm
Hub Reg: 68mm
Num. of holes: 5
Bolt size: 12.9mm
Weight 22.5

Caliper Hardware Kit
41080-0V726

Brake pads
Akebono ACT888

Caliper Seal Kit
CARLSON Part # 15340

Just compare new '06 320mm vs. '04 296mm rotor


OE brakes (left side)


BBU installed (right side)



REAR
Caliper (2005-2007)
44001-EG000; 44001-EG50A RIGHT
44011-EG000; 44011-EG50A LEFT

Splash Shield
44020-EG010 RIGHT
44030-EG010 LEFT

Rotor (2005 – 2008)
43206-EG000 LEFT, RIGHT
Centric #: 120.42088
Rear Rotor Dimensions G35, 350Z (2006 - 2008)
Outer Diameter: 307.7mm
Height: 62.2mm
Nom Thickness: 16.0mm
Min Thickness: 14.0mm
Hub Registration: 68.0mm
Bolt Size 12.7mm
Bolt Circle 5 x 114.3mm

Caliper Seal Kit
CARLSON Part # 15280

Brake pads
ACT905

Caliper Hardware Kit
CARLSON Part # 13399Q

Copper Crash Washers - always replace them!!
Grainger 10x16mm 5ZLU2

Observations
a) Stage 1 - front BBU installed. The Akebono pads provide silent, grab free braking (Hawk HPS were 'graby'). So far I have driven over 60 miles, gently braking to allow new pads to break-in. In stage 2 rear brakes will be retrofitted (soon).
b) Installing dust seal onto caliper piston can be a major, time consuming PITA. The following installation steps worked for me. Clean caliper piston bores, apply small amount of brake fluid and install inner seal into its race. Make sure that seal is positioned squarely into its grove. Apply clean brake fluid to the piston and gently push it into the bore all the way in. Installation of the dust seal requires gentle rotation so that outside lip is gently pushed and remains inside caliper outer grove. Excessive rubber lubricant makes it difficult to install - lip will pop out due to it being very slippery!
c) 06 Master Cylinder has slightly longer travel vs '04, but has same 25.4mm bore diameter.

//RF

 

Nice DIY I have every intention on completing this with my suspension work

 

It all started about 2 month earlier.

Donor calipers - fronts were powder coated while rear have been painted with high temperature engine paint.

Front calipers are from 06 AWD G35 sedan (dual piston design for 320mm rotor) $70 + sales tax and $10 core charge each (IMHO rip-off)!
Rear Calipers were from 06 M35: $90 + shipping


//RF

 

The front calipers you got were not priced too high...I did the same with my car about a year ago and was only able to find a front set of dual piston calipers for $150 Shipped from an 07

 

So what are the parts that you absolutely need. To do the job dont you just need the
1) upgraded calipers
2) larger rotors
3) SS brake lines (preferred)
4) brake pads (with new rotors)

I have an 03 Sedan and I am getting calipers off of a 2006 and have ordered slotted and drilled brake rotors and pads to fit the 06 calipers. I also ordered some SS brake lines just to make the upgrade 100% complete. What else do I need to do. Oh also sand blasting and painting black as well.

Thanks for the help!

 

Please forgive me if I fail to adhere to any forum rules as this is my first post here.

AARONHL - From your post I figure that you may have probably driven close to 20K after you upgraded your brakes to 06 from 04. Could you kindly share if rotors are doing better as compared to the 04?

I am also tired of changing rotors almost every 15K miles in my 2004 G35 non brembo sedan, if this upgrade has worked out for you, I will also go for it.

Thank you!

 

Is this just a direct bolt on upgrade.do you need the 06 caliper bracket also or can you use the 03

 

it's a direct bolt on in the front.

You need the entire 2005-2006 caliper, brake lines and rotors. Nothing from the 03-04 system can be reused.

 

Thanks for the info

 

Somewhat old thread ... But I have a question about the parts needed for the front. Is the caliper hardware kit required for the front if the calipers have the bottom clips? Pads usually come with the shims right? And is the seal kit required if the calipers are in decent shape? I'm not a total noob, but I don't want to spend extra $ if I don't need to. I'd also not want to be stuck without something at install time. Thanks for any help.

 

Seal kit is for rebuilding the calipers. Unless they are leaking, you won't need that.

I don't know what comes with the hardware kit, but it also depends on what came with the calipers. Do you have the bolts and boots and slide pins? IIRC, there are two metal shims for the edges of the caliper where the pad sits. I have a set of OEM pads home, but unsure if there are shims with those. The aftermarket pads I had previously did come with the shims.

 

I am assuming the calipers will use the 2006 caliper brackets - because the rotors are larger. I think the calipers I bought don't come with it. Go figure. I guess that's what I get for looking a dozens of parts and then going back to order. Are the caliper brackets different?

 

Yes. You need the brackets...front and rear.

You can actually reuse your rear calipers...the parts with the pistons. All you are changing is the pad support bracket that relocates the caliper further outboard for the larger rotor.

Up front you need the caliper and the pad support bracket.

 

This is what I've ordered ... It has the bracket I think. Camera angles could have been better.

 

https://g35driver.com/forums/brakes-...-z-brakes.html