Brake Pad: Service and Repair

Front brake pads, replacement (two-piston caliper)
The procedure is applicable to Bendix (DBA) and Girling brake calipers on models to 1991 inclusive.





C1. Jack up and support front of car. Remove wheels
Mark wheel positions if locating studs are not fitted. Place support stands under jacking points.





C2. Remove lower guide sleeve/guide pin bolt
Girling caliper: Hold guide pin with 17 mm socket while removing bolt.





C3. Raise caliper and tie up with wire
Remove pads.

Note: Do not operate brake pedal while pads are removed.

Clean pad mating surfaces in caliper.





C4. Inspect piston dust seals
Replace seals if in poor condition.
When replacing seals, inspect pistons for oxidation or other conditions which may require reconditioning of caliper.
C5. Inspect rubber gaiters on guide sleeves (pins)
Replace gaiters if in poor condition.

Note: Illustration shows caliper with gaiters and guide sleeves of earlier design.

C6. Lubricate guide sleeves (pins) and reinstall in caliper retainer
Use grease, P/N 11 61 825-4.





C7. Inspect disc friction surface and measure disc thickness
Replace disc if component shows signs of severe wear, distortion, variation in thickness or other defects.

Brake disc thickness mm (inch)





New disc: Min. recommended disc thickness when replacing pads; absolute min. thickness











New brake pad with modified backing plate for Bendix (DBA) brake caliper
The new pads are available in two versions, either with or without steel pins in the attachment lugs. Only pads with pins should be stocked as spares.
A new damping spring, P/N 3516813-7, has also been introduced. The spring must always be used with the new pads and should be installed with the arrow pointing upward as illustrated below.
Shim, Bendix (DBA), front





A stainless steel shim, P/N 1387810-3, is installed on cars with Bendix (DBA) front calipers. The shim is intended to minimize squealing or screeching.
Lubricate both sides of the shim with silicone grease, P/N 1161325-4.





C8. Press back brake pistons
Press back pistons slowly using adjustable pliers, taking care to avoid damage to dust seals. Ensure that seals are slightly below piston ends to avoid damage from pad backing plates when caliper is lowered into position.





C9. Install brake pads
Lubricate with light coating (0.1 - 0.2 mm = 0.004 - 0.008 inch) of grease, P/N 1161325-4, applied to backing plates.

Note: Above applies only to Bendix (DBA) pads. Backing plates on Girling pads are provided with anti-squeal coating.

Lower caliper into position and tighten guide sleeve/pin bolt to 34 Nm (25 ft. lbs.).

Note: Use new bolt.

Note: Take care when lowering caliper to avoid puncturing guide pin gaiter, otherwise sliding action may be impaired by entry of water.

Note: Correct torque is extremely important. If torque is too low, joint may work loose. If torque is too high, guide sleeve may be deformed.

Operate brake pedal several times and check fluid level.

Note: Ensure that fluid in master cylinder does not overflow.

Note: Always check for proper caliper sliding function when changing pads.

C10. Refit wheels as per markings
Finger-tighten nuts, then torque diagonally to 85 Nm (63 ft. lbs.).

Test drive car.
Recommend customer to limit hard braking whenever possible during first 500 miles after repair in order to allow the brakes to bed in properly.