Before working on a vehicle's brakes, attach a safety notice to the vehicle to prevent people attempting to operate the brakes. The objective of this procedure is to show you how to safely remove and reinstall a disc brake rotor.
Part 1. Preparation and safety
- Safely remove and reinstall a disc brake rotor.
Whenever you perform a task in the workshop you must use personal protective clothing and equipment that is appropriate for the task and which conforms to your local safety regulations and policies. Among other items, this may include:
- Work clothing - such as coveralls and steel-capped footwear
- Eye protection - such as safety glasses and face masks
- Ear protection - such as earmuffs and earplugs
- Hand protection - such as rubber gloves and barrier cream
- Respiratory equipment - such as face masks and valved respirators
If you are not certain what is appropriate or required, ask your supervisor.
- Brake components can be very hot even though they do not appear to be. Take precautions against burns when working on them.
- Always follow the manufacturer’s procedure and specifications.
- Do not allow the disc calliper to hang by the brake hose. Support it with a piece of wire.
- Properly clean and dispose of brake dust.
- Seat the brake pads in position before driving the vehicle.
- Make sure that you understand and observe all legislative and personal safety procedures when carrying out the following tasks. If you are unsure of what these are, ask your supervisor.
Points to note
- Clean the mating surfaces of the hub and rotor before assembly.
- If the rotor is being replaced with a new rotor, clean it according to the installation instructions.
- Test the brake pedal to seat the brake pads before driving the vehicle.
Part 2: Step-by-step instruction
- Attach safety notice
Before working on a vehicle’s brakes, attach an appropriate label to the vehicle to prevent accidental actuation of the brake caliper while it is removed from the hub.
- Prepare the vehicle
Safely raise the vehicle and remove the wheel.
Remove the brake pads and caliper; making sure the caliper is located safely away from the rotor.
- Remove the rotor
Remove the rotor by unbolting the securing device and sliding it away from the wheel hub.
- Prepare the new rotor
Before installing the new rotor, clean it thoroughly in a component washer to remove any storage preservative agents. Clean any dirt, rust and debris from the hub mating surface. Secure the rotor to the hub and rotate it by hand to ensure it rotates freely.
- Reassemble the wheel
Refit the brake caliper and disc pads. Apply the brakes several times to readjust the caliper pistons. Refit the road wheel & safely lower the vehicle.
- Road test the vehicle
Ask your supervisor to check the brake system pedal pressure, fluid levels, and visual signs of leaks. When the supervisor is satisfied, the vehicle should be road tested by a qualified person to ensure the integrity of the braking system.