Brake Replacement Step-by-Step

Brake replacement is a great way for the home mechanic to save money on vehicle service, and an essential skill for beginners. Luckily most automotive brake systems can be serviced by simple hand tools, and require no special knowledge beyond access to the vehicle's service manual.

Removal of Brake Pads

Begin by parking the vehicle on a level surface and blocking the rear wheels. Lift the front of the vehicle according to instructions listed in the owner's manual and support with jack stands placed underneath the frame. Remove the front wheels and tires. Examine the caliper. There will usually be two bolts that connect the caliper to the caliper mounting brackets. Loosen these bolts enough to remove the caliper. On most models it will not be necessary to remove the bolts from the mounting brackets. If you have difficulty pulling the caliper off the rotor, use a c-clamp to drive the piston back into the caliper. Place the bottom of the c-clamp on the raised round portion of the caliper on the inboard side of the caliper. Place the other end of the c-clamp on the back of the outboard brake pad. As you tighten the clamp it will drive the piston into the caliper, making it much easier to remove. Never allow the brake caliper to hang by the hydraulic brake hose. Doing so could cause damage to the hose or introduce air into the hydraulic circuit. Always secure the caliper with steel wire to the frame.

Removal of the Brake Rotor

Procedures for removing the brake rotor will vary by make and model, but generally fall into two categories. One is where the rotor rests freely on the lug nut studs and is retained by the lug nuts and brake caliper, the other is where the wheel bearing races are integrated into the brake rotor. In the first case the rotor can simply be pulled off the wheel hub once the caliper has been removed. In the second case use a flat screwdriver to pry off the grease cap. Remove the cotter pin and castle nut and pull the rotor off. Be careful, as the wheel bearings will come off with the rotor; make sure not to damage them.

Installation of a Brake Rotor

When you are installing the new rotor, don't get any grease, dirt or oil on the surface of the rotor. In cases where the rotor sits freely on the lug nut studs, you can simply slide the new rotor in place of the old one. If your rotors have integrated wheel bearing races, apply some fresh grease to the bearings before loading them into the new brake rotor. Slide the rotor onto the hub, then reinstall the castle nut. Follow the torque specifications outlined in the vehicle's service manual when tightening the castle nut. Failing to do so could cause damage to the bearings. Install a new cotter pin and reinstall the grease cap.

Installation of Brake Pads

If you did not drive the piston back into the caliper during removal, do so now. Reinstall the old inboard brake pad to avoid damaging the piston while driving it back into the caliper. Load the new brake pads into the caliper. In most cases the inboard pad will have a clip that fits into the brake caliper piston, and the outboard pad will have a clip that secures it to the caliper. Slide the caliper over the rotor and tighten the two bolts that connect the caliper to the caliper mounting bracket. Reinstall the wheels and tires and lower the vehicle. Turn on the engine, and pump the brake pedal a few time to allow the caliper pistons to adjust to the new pads.