2002-2006 Acura RSX Brake Job Guide: Symptoms, Costs and the Right Parts

By Core Brake Parts Tech Team — Circleville, OH warehouse

A brake job on a 2002-2006 Acura RSX means pads and, usually, rotors on a four-wheel disc system, and the first thing to know is which trim you have: the RSX Type-S uses a larger 300 mm front rotor than the base RSX, so front parts are not interchangeable between trims. The fronts wear first and are an easy driveway job; the rears are simple too, as long as you know how to retract the rear caliper piston without damaging it.

How the RSX Brake System Is Laid Out

Every RSX from 2002 to 2006 left the factory with disc brakes at all four wheels and a three-channel anti-lock braking system. There are no rear drums on this car, so a full brake job covers two axles of pads and rotors.

• Front brakes: ventilated rotors with single-piston sliding calipers. The Type-S front rotor is 300 mm across and 25 mm thick new, with a 23 mm minimum thickness stated for the replacement rotor. The base RSX uses a smaller front rotor, so order by trim, not just by year.
• Rear brakes: smaller solid rotors with a sliding caliper that also carries the parking brake mechanism. The rear pads last longer than the fronts because the front axle does most of the stopping.
• Hydraulics: a vacuum brake booster and master cylinder running DOT 3 brake fluid, which is the fluid Acura itself specifies in its service bulletin for this car.

For 2005 Acura fitted a larger-diameter master cylinder, a stiffer brake pedal and a shorter pedal stroke. The pads and rotors did not change because of it, but a 2005-2006 pedal will feel firmer than an early car's, which is worth knowing if you are comparing two RSXs and wondering whether one has a problem.

Symptoms That Your RSX Is Due for a Brake Job

• High-pitched squeal while driving that goes away when you brake: the pad wear indicator tab is touching the rotor. Plan the job soon.
• Grinding or a harsh metallic growl when braking: the friction material is gone and the steel backing plate is cutting the rotor. Stop driving on it; the rotors are now scrap.
• Steering wheel shimmy under braking: front rotor thickness variation, often called a warped rotor. On a light car like the RSX this shows up in the wheel quickly.
• Pulsing felt in the seat or pedal with a steady wheel: points to the rear rotors.
• Car pulls to one side: a sticking front caliper slide pin or a seized caliper piston. Look for one pad worn much more than its partner.
• Hard pedal that needs extra effort to stop: this is a booster problem, not a pad problem. See the recall section below.
• Soft or sinking pedal: air or moisture in the fluid, a leaking line or hose, or a master cylinder bypassing internally.

Front vs Rear: What Wears and What to Replace Together

The RSX is front-wheel drive with most of its weight over the nose, so the front pads normally wear out well before the rears. It is common to go through two sets of front pads for every set of rears. Always replace pads in axle sets, both wheels together, so the car stops straight.

Whether to replace rotors comes down to measurement. Measure the rotor with a micrometer at several points: if it is at or below the minimum thickness stamped on the rotor (23 mm on the Type-S front), or it has deep scoring, heat cracks or a pulsation you can feel, replace it. Most shops now replace rather than resurface these rotors, because a machined rotor starts closer to minimum and runs hotter. If your pads were down to metal, the rotors are done.

Replace or service at the same time:

• Hardware: new abutment clips and shims, and clean and re-grease the caliper slide pins with a silicone brake grease. A brake hardware kit is inexpensive and cures most noise complaints.
• Brake fluid: DOT 3 absorbs moisture over time. If the fluid is dark or has not been changed in years, flush it while the wheels are off.
• Rubber hoses: this car is now around 20 years old. Check for cracking and bulging and replace any hose that looks tired with new brake hoses.
• Calipers: if a piston is seized, a slide will not free up, or the rear parking brake mechanism is binding, a reman brake caliper is the fix.

If you want to do both axles at once, ordering pads and rotors together takes the guesswork out of it. Browse brake pads for the RSX and replacement brake rotors, and pick the Type-S or base listing that matches your car.

How Hard Is the Job?

Front brakes are a beginner-friendly job. Two caliper bolts come out, the caliper lifts off, the pads come out of the bracket, and the bracket comes off to free the rotor. Honda rotors are held to the hub with small retaining screws that often seize; an impact driver and penetrating oil usually free them. Push the front piston back with a C-clamp or piston tool before fitting new pads.

Rear brakes are where most first-timers get stuck. The rear caliper houses the parking brake, and its piston does not simply press straight back like a front piston. It has to be turned clockwise as it retracts, using a caliper piston tool that engages the slots in the piston face. Forcing it with a C-clamp can damage the internal mechanism and ruin the caliper. Release the parking brake before you start.

Finish by torquing caliper bolts and lug nuts to the values in the factory service manual, pumping the pedal until it is firm before the car moves, and bedding the new pads in with a series of moderate stops so they transfer an even layer onto the rotors.

Recall Check: 2006 RSX Brake Booster

Acura issued a safety recall (NHTSA campaign 13V-246, Acura service bulletin 13-025) on certain 2006 RSX models because the brake booster may not have been assembled properly and can leak vacuum. A leaking booster gives a hard pedal that needs more force to stop the car. The dealer remedy is to inspect the booster and replace it if needed. If you have a 2006 RSX with a hard pedal, check your VIN for an open recall before buying parts. New pads and rotors will not fix a booster leak.

What Drives the Cost of an RSX Brake Job

The price of the job moves on a few clear factors:

• Pads only vs pads and rotors: adding rotors raises the parts bill substantially, but is usually necessary on a car this age.
• One axle vs both: most visits are fronts only. Doing both axles is the most parts, but the least labor per wheel if you do it all at once.
• Trim: Type-S front rotors are larger and heavier than base RSX rotors and typically cost more.
• Extras: a seized caliper, a fluid flush or new hoses add parts and time.
• Labor: doing it yourself removes the largest single line item. The rear piston tool is the only special tool most owners need.

Frequently Asked Questions

Are Type-S front rotors the same as base RSX rotors?

No. The Type-S uses a 300 mm front rotor that is larger than the base car's, with its own caliper bracket. Order front parts by trim. If you are unsure which you have, check the badge or measure the old rotor.

Does the 2002-2006 Acura RSX have rear drum brakes?

No. Every RSX has four-wheel disc brakes with ABS, so the rear job is pads and rotors, not shoes and drums.

Why will my RSX rear caliper piston not push back in?

Because the rear caliper contains the parking brake mechanism and the piston must be turned clockwise while it retracts. Use a caliper piston tool and make sure the parking brake is released.

What brake fluid does the Acura RSX use?

DOT 3. Acura's own service bulletin for the RSX calls for Acura Genuine DOT 3 brake fluid.

My 2006 RSX has a hard brake pedal. Is it the pads?

Unlikely. A hard pedal points to low booster assist. Certain 2006 RSX models are covered by a brake booster recall, so check your VIN for an open recall first.

Should I replace rotors every time I replace pads?

Not automatically. Replace them if they are at or under minimum thickness, scored, cracked or causing pulsation. On a car this old with original or second-set rotors, they often are.

Sources

1. NHTSA / American Honda Service Bulletin 13-025 - 2006 RSX brake booster recall, hard pedal symptom, DOT 3 fluid
2. Conceptcarz: 2005 Acura RSX - four-wheel disc brakes, three-channel ABS, 2005 master cylinder and pedal changes
3. DBA 4000 T3 front rotor for RSX Type-S - 300 mm diameter, 25 mm thickness, 23 mm minimum thickness
4. RacingBrake RSX Type-S front rotor kit - 300 x 25 mm front rotor size for the 2002-2006 RSX Type-S