Brakes or Swap?

[Damkid]

Ya a friend at a junkyard always helps :lol: but I still don't rely on friends for even that... But my friends aren't dependable though lol

[redspire]

Falken, contact a member on here named bobbyspider. Awhile back he had an entire aspire swap at the ready. He may still have it.

[falkenfighter]

Interesting, any clue if hes local? Shipping would be crazy

[redspire]

Hes in pa so definitely not local. Just figured id throw it out there if you'd rather pay shipping than try finding an automatic aspire. Maybe just get the essentials from bobby if he has them then order some parts new like rotors, pads, calipers etc. The car he tore it from was my old aspire and i know for sure that some of the parts i never got around to replacing. Good luck though!

[falkenfighter]

Does the aspire have to be auto?

[Damkid]

Nope, the only difference I can think of is the auto aspires had slightly thicker rotors... I'm not sure if the calipers were slightly wider to accommodate the thicker rotor or not though

Basically if you get an aspire setup and don't know if you have a setup from an auto or manual... Just get rotors for a manual, the auto calipers will still compress against the manual rotors and work just fine.... That's what I would do at least

[falkenfighter]

I see, thats sort of odd. Ill probably get whatever they have

[Safety Guy]

The difference between manual and auto Aspire front brakes is:

-thicker rotors, which weigh more (1.5 pounds per side)
-wider caliper brackets (calipers should be the same, but they usually are sold with the brackets)

Auto Aspire rotors are essentially the same as early Kia Rio rotors.

Chris may be right about using manual rotors with auto caliper/brackets, but I'd double check that to be safe.

Karl

[Bert]

Festy brakes are meagre at best and the fronts are an onerous chore to deal with when you're looking to replace rotors. What's nice about the Aspire swap is that the grab and longevity of brake pads and shoes improves considerably, rotors are suddenly a snap to replace and a whole new world of rims and tires, outside the realm of boat trailer 12 inch, opens up. If a bigger engine and better handling is in your future plans then by all means start scouting around for an Aspire donor in order to get the suspension/springs/brakes and sway bar, and gas tank if it's a 2 door. And don't forget to convert over to Kia Rio top hats on the front struts while you're at it.

[Bert]

Auto Aspire rotors are essentially the same as early Kia Rio rotors.
Karl

I have to ask: Does this mean I can adapt to Rio rotors, pads and calipers once my supplier tells me Aspire parts are prohibitively expensive and/or no longer available?

[Safety Guy]

Early Rio rotors, calipers and pads are all the same as auto Aspire. "Early Rios" are 2001 and most 2002 models. Easy check is to count the strut mount bolts: two bolts vs. later three bolts (late 2002 and 2003 to 2005). Also, IIRC, 2003 was a transition year in which both 1.5 and 1.6 motors were offered, with the larger engines having the upgraded parts and three bolt mounts.

Escort tie rod ends can be used in swaps and are usually cheaper as well (1991 to '94), and are about the same as Aspire (and Rio??).

I'm also pretty sure those years Escort calipers and pads are about the same as auto Aspire/early Rio. You'd want to double check that though.

As for struts, I doubt I'll ever go back to Festiva or Aspire front struts or mounts. My plans are for early Rio front struts and mounts, with either cut Aspire or cut Rio springs, unless I'm doing a coil over setup.

Keep in mind Rio strut piston tops are designed to perfectly fit the hole in Rio strut mounts, whereas Aspire strut piston tops will need adapting to Rio mount holes.

Repeating for those who don't know, Rio strut mounts have real ball bearings, while Aspire and Festiva strut mounts have plastic washer "bearings." Rio strut bearings are vastly superior, and used ones will be at least four years newer than used '97 Aspire mounts!

A nice condition, low miles early Rio could theoretically provide your Festiva/Aspire upgrade at low cost:

-struts and mounts
-knuckles
-rotors, calipers and pads
-springs to cut
-brake hoses

All front end parts, of course. Rear end is quite different.

Also, I would tend to go with new brake lines, rotors and tie rod ends.

Note: Aspire and Rio brake hoses will fit Aspire and Rio strut brackets. Festiva hoses won't (will need to be ziptied at the bracket).

Several folks have done the "big brake upgrade," which is the later model Rio knuckles, rotors and calipers. Still somewhat new advance for us, so be careful how you do it and test it out!

Karl

[Bert]

Early Rio rotors, calipers and pads are all the same as auto Aspire. "Early Rios" are 2001 and most 2002 models. Easy check is to count the strut mount bolts: two bolts vs. later three bolts (late 2002 and 2003 to 2005). Also, IIRC, 2003 was a transition year in which both 1.5 and 1.6 motors were offered, with the larger engines having the upgraded parts and three bolt mounts.

Escort tie rod ends can be used in swaps and are usually cheaper as well (1991 to '94), and are about the same as Aspire (and Rio??).

I'm also pretty sure those years Escort calipers and pads are about the same as auto Aspire/early Rio. You'd want to double check that though.

As for struts, I doubt I'll ever go back to Festiva or Aspire front struts or mounts. My plans are for early Rio front struts and mounts, with either cut Aspire or cut Rio springs, unless I'm doing a coil over setup.

Keep in mind Rio strut piston tops are designed to perfectly fit the hole in Rio strut mounts, whereas Aspire strut piston tops will need adapting to Rio mount holes.

Repeating for those who don't know, Rio strut mounts have real ball bearings, while Aspire and Festiva strut mounts have plastic washer "bearings." Rio strut bearings are vastly superior, and used ones will be at least four years newer than used '97 Aspire mounts!

A nice condition, low miles early Rio could theoretically provide your Festiva/Aspire upgrade at low cost:

-struts and mounts
-knuckles
-rotors, calipers and pads
-springs to cut
-brake hoses

All front end parts, of course. Rear end is quite different.

Also, I would tend to go with new brake lines, rotors and tie rod ends.

Note: Aspire and Rio brake hoses will fit Aspire and Rio strut brackets. Festiva hoses won't (will need to be ziptied at the bracket).

Several folks have done the "big brake upgrade," which is the later model Rio knuckles, rotors and calipers. Still somewhat new advance for us, so be careful how you do it and test it out!

Karl

This veritable wealth of information needs to be stickied. Three years in to having done these mods I can personally vouch for the Rio top hat swap as being the most cost-effective steering improvement you can make. I did not swap in Rio struts at the time but this would have made for a direct fit through the hats as opposed to the sleeving and bearing contact shimming required when using Aspire/Festy-type struts.

[Safety Guy]

According to Rockauto's parts listings, the "early" and "late" Kia Rio strut dividing line is July or August of 2002.

If you're at the 'yard you simply check the number of mounting bolts at the strut mount.

Checking the numbers on the brake rotors, I also figure that's when they switched from the 235mm diameter rotors (22mm thick) to the larger 254mm rotors (24mm thick). However, the Rockauto 2003 Rio rotor section lists at least one choice of the old 234mm ("small") rotor. That could be a mistake.

In 2003, Rios had a transition year in which they came with both the old 1.5 engine and the new 1.6. All the 1.6 engined cars use the bigger brakes.

As far as the rear suspension goes, it is totally different, though one of the rear bearing races is the same one used on Festivas and Aspires. Also, the rear springs, which are somewhat cone shaped, could possibly be used on our cars if they would fit with the smaller end of the cone on the top. Just a guess, mind you.

Karl

[advantage]

so if i read all this correctly, an aspire rear beam will fit? I have access to a 41k piece.
thanks
rick

[Team Lightning]

You need the Aspire beam complete with the parking brake cable. Some people change the hoses on the rear beam. On mine I enlarges the mounting holes for the hoses and used my Festiva hoses. If you use the Aspire rear springs it will be stiffer and it will sit higher by an inch or 2.