Ok, I (finally) got around to changing the pads on my 89 745Ti. Problem: I've gotten the rear calipers off, greased everything up, and I go to put the reassembled caliper with pads and all back onto the car and bam, not enough room between the pads. The pads I ordered from Volvo, so there's not fitment questions in my mind. I'm wondering what I can do? I've noticed that the piston is kind of "always on" as in always maintaining pad to rotor contact, no matter how thick the pad, without the pedal being depressed. Well I've installed new pads that are substantially thicker than the old ones, but the piston is still set for the thickness of the old pads. Do I have to bleed the brakes? Or is it just a matter of messing with things until I get it right?

Oh, and they're ATE calipers.

Moving to the front of the car. Is there a trick to getting the bolts that hold the caliper to the wheel assembly off? I have put my entire body into it, breaking a cheap ratchet, and bending a breaker bar. Before this, I bent a 10 mm allen wrench. I went ahead and put PBR penetrating stuff on both of them (no I didn't let it hit the braking surface), is there something else I ought to try? (Front calipers = Girling, I have ABS)

Thanks!

Ryan