308mm Lotus Sport / AP Racing rebuild kit - LotusTalk - The Lotus Cars Community
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post #1 of 22 (permalink) Old 12-04-2011, 02:53 PM Thread Starter
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308mm Lotus Sport / AP Racing rebuild kit

Starting in 2008, the Exige-S 240 came with 308mm Lotus Sport / AP Racing front calipers. I think these are the same calipers as the previous Exige S2 Cup cars, and the 2008-2011 240, 260, and an option on 211 cars.

On my car the piston dustboots on the front calipers finally became crispy and have disintegrated. They have taken lots of abuse so I thought it best to replace all the seals. Lotus dealers do not sell rebuild kits so I had to go to AP Racing to find out the part #'s needed to rebuild the calipers.

Hopefully this might save you a week's worth of emails to get the answer you need.


These are the AP Racing part numbers that I found on my calipers:
CP7635-3S0BGLOT -Left front
CP7635-2S0BGLOT -Right front

If you have the same part numbers written on your calipers, this is the part number you need to order the rebuild kit. Order one for each side:

Seal repair kit # CP4525-EH
Each kit includes:
Pressure seals x4
Boot seals x4
Bleed screw O/rings x2
Bleed screw caps x2
Re-sealing instructions

If you want to replace the pistons (1.25 x 36mm) the AP part numbers are:
CP7635-106 (x2 per caliper)
CP5315-103 (x2 per caliper)

Now you can call up a AP Racing dealer and get what you need!
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Click links to see my 2008 Lotus Exige-S 240 , '99 M3, 505rwhp '89 Mustang ( sold) , '05 WRX STI ( sold) homepages or here for my spin compilations (ispunuwin & ispinuwin2!)!
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post #2 of 22 (permalink) Old 12-04-2011, 03:01 PM
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Awesome post! Thanks! How much does the rebuild kit cost? And do these calipers come with aluminum or stainless pistons?
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post #3 of 22 (permalink) Old 12-08-2011, 06:17 PM Thread Starter
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The seal repair kit retails for 24.16 each.
The pistons are aluminum alloy (retail price unknown).


Click links to see my 2008 Lotus Exige-S 240 , '99 M3, 505rwhp '89 Mustang ( sold) , '05 WRX STI ( sold) homepages or here for my spin compilations (ispunuwin & ispinuwin2!)!
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post #4 of 22 (permalink) Old 05-25-2012, 01:30 PM
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I purchased a used kit here on the boards & off of an Exige S 260 Sport. The part number looks to be similar, but not identical.
I called Stillen & they cannot find in their system the Seal Repair Kit Part# you listed; crossing my fingers.

Does anyone know if across the years from 2008 on; if the AP Racing Front Calipers are the same - that is what the OP is stating so Im thinking the same?

I plan on powder coating the brakes so would like to replace all seals after the process. I believe the pistons should still be fine especially how the kit I bought only has 100mi or so on it.

Here is the kit I picked up: https://www.lotustalk.com/forums/f95/...system-114432/
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post #5 of 22 (permalink) Old 05-25-2012, 02:16 PM
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Check with Essex Essex - Home page

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post #6 of 22 (permalink) Old 05-26-2012, 12:52 PM
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^ Thanks for the reference, will do.
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post #7 of 22 (permalink) Old 05-26-2012, 08:28 PM Thread Starter
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I remember calling Stillen too and they just told me they didn't have it. Instead of ordering it for me they said it would be better for me to call British Racing Imports and Track Services, Inc. BRITS INC and order it... and that is where I ended up buying the kits from.


Click links to see my 2008 Lotus Exige-S 240 , '99 M3, 505rwhp '89 Mustang ( sold) , '05 WRX STI ( sold) homepages or here for my spin compilations (ispunuwin & ispinuwin2!)!
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post #8 of 22 (permalink) Old 05-26-2012, 10:26 PM
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^ I'll check here as well, thanks for the reference.

What about the rear Brembo calipers; do we have a way to get replacement seals/rebuild kit for these as well?
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post #9 of 22 (permalink) Old 05-28-2012, 04:16 AM
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Here is the real information on the front AP Racing calipers designed for Lotus Cup cars. It has part number descriptions and all on this customer drawing from AP Racing.cp7635-1cd - Sheet1.pdf
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post #10 of 22 (permalink) Old 05-31-2012, 12:53 PM
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Originally Posted by <@@> View Post
Here is the real information on the front AP Racing calipers designed for Lotus Cup cars. It has part number descriptions and all on this customer drawing from AP Racing.Attachment 185830
Good post! Thanks for sharing

Any idea why my part numbers are slightly different? Anyone here might have a matching set as mine?


LF = CP7635-7S0BGLOT
RF = CP7635-6S0BGLOT
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post #11 of 22 (permalink) Old 05-31-2012, 07:30 PM
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Zone 2F of that drawing only shows -2,-3,-4 and -5...but that drawing's last revision was in 2010...so -6 and -7 may be valid number, but I could not find a real explanation of what they meant either. That drawing also shows that Lotus only bought -2 and -3… Do your calipers have Lotus P/N A120J4001F on them? Or do they have A128J4001F as a P/N on them? If they have A120J4001F, then my guess is that there is some minor change like paint or finish difference between the -2 and -3 and the -6 and -7. If neither Lotus number is there, then I think you’ve got an aftermarket caliper.
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post #12 of 22 (permalink) Old 06-01-2012, 08:21 AM
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l got confirmation from Stillen on the following; looks like I am in the GO for the part numbers listed above for the seal repair kit.

LF = CP7635-7S0BGLOT
RF = CP7635-6S0BGLOT

The first 4 digits CP7635 identifies the caliper, after the dash, 7S0BGLOT/6S0BGLOT identifies the caliper position (LH/RH, leading/trailing), paint code, with or without anti knockback spring and customer.

Question: What is the function of the "anti-knockback spring"?
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post #13 of 22 (permalink) Old 06-01-2012, 11:23 AM
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It goes inside the caliper, behind the piston, to give a little pressure on the discs...so that the disc will not knock back the pistons when it is slightly out of round. It gives a little less pedal travel at the cost of a little drag.
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post #14 of 22 (permalink) Old 06-01-2012, 12:34 PM
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Originally Posted by <@@> View Post
It goes inside the caliper, behind the piston, to give a little pressure on the discs...so that the disc will not knock back the pistons when it is slightly out of round. It gives a little less pedal travel at the cost of a little drag.
Very cool - makes sense! Thanks for the explanation
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post #15 of 22 (permalink) Old 06-09-2012, 10:33 PM
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l got confirmation from Stillen on the following; looks like I am in the GO for the part numbers listed above for the seal repair kit.

LF = CP7635-7S0BGLOT
RF = CP7635-6S0BGLOT

The first 4 digits CP7635 identifies the caliper, after the dash, 7S0BGLOT/6S0BGLOT identifies the caliper position (LH/RH, leading/trailing), paint code, with or without anti knockback spring and customer.

Question: What is the function of the "anti-knockback spring"?
Thought this might help for info; I took apart my calipers today & found no knockback spring. So this part number should reference those calipers without one. Im thinking its the "G" in the part number.
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post #16 of 22 (permalink) Old 06-10-2012, 04:33 AM
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In the drawing that I've attached to post #9, none of the calipers listed there have ANTI KNOCK BACK SPRINGs...see zone 2J. So I don't think that the G has anything to do with that.
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post #17 of 22 (permalink) Old 06-12-2012, 11:30 AM
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I dont know why I didnt find this sooner, this just simplifies everything. If you need to replace seals for your AP 4pot; buy this:

AP-Racing 4-pot caliper Refurbishment kit (All cars with OE 4-pot calipers) [AP4PREF] - &euro;34.10 : Elise Shop, Performance parts for your Lotus Elise
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post #18 of 22 (permalink) Old 07-01-2012, 09:53 AM
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FYI...this is what the anti knock spring looks like...I just stumbled accross it.
http://www.eliseparts.com/products/s...knock-springs/

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post #19 of 22 (permalink) Old 07-03-2012, 04:53 PM
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^ Yeah, saw that at eliseparts.com. Upon disassembling the brakes mine did not have these.
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post #20 of 22 (permalink) Old 07-04-2012, 08:59 AM Thread Starter
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Mine did not have the parts in post #18 either.


Click links to see my 2008 Lotus Exige-S 240 , '99 M3, 505rwhp '89 Mustang ( sold) , '05 WRX STI ( sold) homepages or here for my spin compilations (ispunuwin & ispinuwin2!)!
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