October 20, 2021

Professor John Fisher

English Professor
San Juan College
4601 College Blvd
Farmington, NM 87401

Dear Professor Fisher,

In regards to the technical manual project, I am sending you the full manual detailing Removing
and Replacing Automotive Brake Components.

The report is a detailed guide on replacing or repairing 2 common automotive brake system
parts. These being the brake pads and the brake rotor. The purpose of this document is to
demonstrate and guide you through the proper and manufacturer approved method. This
manual is not intended for individuals who do not have knowledge of basic hand tools. It is
intended for beginners with basic knowledge of hand tools and automotive fasteners. (Nuts,
Bolts, Studs, Ect.)

This manual will be made as user friendly as possible and is organized in chronological order
and details all of the required tools and materials needed to complete the work. Due to the
nuances of each vehicle being different in small ways, this guide is not for one specific model or
vehicle, rather it is a general guide designed to cover the basics of brake maintenance.

I would like to add that if you encounter any difficulties or confusion due to the nuances of your
specific vehicle, There is a variety of service literature for your year, make, and model of
vehicle. I would be more than happy to provide those documents should you need them. You
can contact me at any time through my email and I will respond as soon as I can.
Contact me through phone or email at (505)215-9298 or tyler.howell1122@gmail.com

Kind Regards,

Tyler Howell

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 Removing and Replacing Automotive
Brake Components

Submitted to

Professor John Fisher

San Juan College
Farmington, New Mexico

October 25th, 2021

Written and composed by

Tyler Howell

This manual is designed to explain in broad terms the replacement and

maintenance of common automotive brake components. More specifically, the
replacement of the brake pads and rotors. Once again the manual is NOT designed to
cover the nuances and specifications of an individual make or model of vehicle. Rather,
this manual covers the general knowledge required to perform the maintenance on a
variety of different vehicles. However be aware that due to the nature of each vehicle
being different in small ways that this manual may not cover each of those said details

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 Table of Contents

1.0 INTRODUCTION …………………………………………... 5

1.2 Background …………………………………………... 5
1.3 Scope …………………………………………... 5
2.0 Lifting the …………………………………………... 6
Vehicle
2.1 Finding the …………………………………………... 6
Proper Jack Points
2.2 Supporting the ………………………………………….. 6
Vehicle
2.3 Inspecting the ………………………………………….. 7
Vehicle

3.0 Removing the ………………………………………….. 7

wheels
3.1 Inspecting the …………………………………………... 8
brakes
4.0 Brake Caliper ………………………………………….. 10
Overview

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4.1 Removing the ………………………………………….. 10
Brake Caliper
4.2 Removing the …………………………………………... 11
Brake Pads
4.3 Assessment of …………………………………………. 12
the Brake Rotor
5.0 Removing the …………………………………………. 13
Brake Caliper
Bracket
5.1 Removing the ………………………………………….. 13
Brake Rotor

5.2 Cleaning the ………………………………………….. 14

Hub - Preparing for
Reinstallation
5.3 Installing New …………………………………………... 14
Components
6.0 Conclusion …………………………………………. 17

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1.0 Introduction
The following content gives a broad overview of the purpose, background, and
scope of this document.

1.1 Purpose
This manual is designed to give a general overview of the steps and processes
involved in changing and maintaining automotive brake components. This manual will
explain step by step the replacement of both the brake pads and the brake rotor.
(Please note this manual is covering rotor type brakes. Drum brakes will NOT be
covered in this manual.)

1.2 Background
Brakes being one of the most important mechanical components of your vehicle
means it is critical to understand how these systems work and as well as how to
perform the basic and preventative maintenance to keep the brake system in good,
functional condition. This manual will detail each step involved in this maintenance on
most vehicles and explain how the brake system works fundamentally

1.3 Scope
This manual explains the general procedures involved in repairing most
automotive brake systems. This manual does NOT go into the details and nuances of
each individual make and model of vehicles. This manual does NOT go into detail into
drum type brake systems. This manual is not intended to teach an absolute beginner
automotive maintenance. The user must have a basic knowledge of common hand tools
and automotive fasteners. (Nuts, Bolts, Studs, Ratchets, Wrenches, Ect.)

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2.0 Lifting the Vehicle

2.1 Finding the Proper Jack Points

The first step to doing almost any work on a vehicle is to jack the vehicle off the
ground and support it with jack stands. Depending on the vehicle the best places to lift
the vehicle with the jack will either be: ( Frame Rails, Pinchweld, or subframe)

Side Note: Most Rear Wheel Drive vehicles can be lifted from the rear by the differential

2.2 Supporting the Vehicle

Once the vehicle is lifted off the ground it is very important to support the vehicle
with jack stands. Supporting the vehicle with only a manual or hydraulic jack is VERY
dangerous. Hydraulic jacks can and do fail. It is always advised to support the vehicle
with the jack stands and jack to ensure your safety.

Side Note: Jack stands should be placed on the same areas as the jack. I.e. Frame
rails, subframes, pinch welds
( NEVER SUPPORT A VEHICLE ON JACKSTANDS FROM THE CENTER. THIS
COULD CAUSE THE VEHICLE TO BECOME UNBALANCED AND FALL )

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2.3 Inspecting the Vehicle
Now that the vehicle is properly lifted, the vehicle should be inspected to make
sure the vehicle is safe to work around. Take the following steps to ensure the vehicle is
safely lifted.
● Make sure the vehicle is level
● Make sure all of the jack stands are sitting flat against the ground
● Make sure the jack stands points are not being crushed or bent by the
weight of the vehicle
● Lightly shake the vehicle by pushing against the fender to ensure the
vehicle is steady and not at risk of falling.

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3.0 Removing the wheels
In order for us to access the brakes we must remove the wheel. The wheel is
held on by 4-6 lugnuts. The lugnuts are removed with a socket wrench or an impact
gun. (If you do not have access to an impact, loosen the lug nuts while the vehicle is on
the ground. If you try to loosen the lug nuts with a lug wrench while the vehicle is lifted,
The wheel will just spin.)

3.1 Inspecting the brakes

Once the wheel is off you will be able to get a better view of the brakes. Next you
will need to visually inspect the brakes to assess the next steps in maintenance.
Brake pads need replacement if there are any signs of:
● Brake material being less than 3mm in depth
● Brake pads rusting
● Brake pads wearing unevenly

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Brake rotors need to be replaced if there are any signs of:
● Gauged or scorn brake rotors
● Severe rust (Note that brake rotors will build up light layers of rust when the
vehicle has not been moved in 1-2 days. This is normal and lightly rusted rotors
are cleared of rust by the brake pads while braking.

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4.0 Brake Caliper Overview
The brake caliper is the part of the brakes that contains the hydraulic piston that
allows the brakes to function. The brake line connects to this part of the brakes and
supplies the hydraulic fluid (brake fluid) to the caliper piston.

4.1 Removing the Brake Caliper

The brake caliper is typically held in place by 2 bolts or nuts on the top and
bottom of the guide rods that the caliper slides on. Once these two fasteners are
removed, the top half of the caliper can be removed.

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(DO NOT LET THIS PART OF THE BRAKE CALIPER HANG BY THE BRAKE LINE,
THIS COULD DAMAGE THE BRAKE LINE AND CAUSE A BRAKE FLUID LEAK)

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Always hang the caliper with an elastic cord or rest it on a block that does not put any
strain on the brake line as seen in figure 1-1.

Figure 1-1

4.2 Removing the Brake Pads

After removing the brake caliper, the brake pads will be able to be removed. The
brake pads sit in tracks in the brake caliper bracket and can be removed by hand. Some
automotive brakes have small metal inserts that are placed in between the rough cast
metal of the caliper and the brake pads themselves. These are important to replace to

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stop any unwanted brake noise.

4.3 Assessment of the Brake Rotor

It is important to note that if your vehicle does not need new brake rotors, then
you do not need to follow the steps involved in removing it. If this is the case, disregard
the following instructions until 5.3 Installing the Brake Pads.

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5.0 Removing the Brake Caliper Bracket
On most vehicles, there will be a mounting bracket that mounts the floating
caliper to either the steering knuckle for the front brakes, or the rear axle housings. On
some vehicles, the removal of this bracket is required to remove the brake rotor. This
part is typically held on with 2 14mm bolts.

5.1 Removing the Brake Rotor

The brake rotor on most cars is held in place by the wheel and lugnuts. On some
cars such as European manufacturers, The brake rotor will be held to the hub with a

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single, countersunk, bolt. Once the rotor is free, it can be pulled straight off the hub.

(Note: In some cases involving rust, a hammer may be required to break rusty rotors
free.)

5.2 Cleaning the Hub - Preparing for Reinstallation

Now that the brakes are completely disassembled, It is important to clean off the
hub of rust and debris with either a wire brush or medium grit sandpaper. This ensures
that the rotor will sit flush against the hub. If it is uneven in any way it could create

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vibrations while braking.

5.3 Installing New Components

I. Installation of the new parts is essentially the reverse of disassembly. Whether or
not you are replacing or reusing your brake rotor, The rotor is installed first by
sliding it over the wheel studs. If your brake rotor has a bolt that aligns it to
the hub, REMEMBER TO REINSTALL THE BOLT.

II. Next Reinstall the brake caliper bracket. Remember to check service
information for proper torque specifications.

III. Install the brake pads and pad guides into the brake caliper bracket. ( It is not
required however it is recommended to apply copper anti-seize where the brake
pads move in their track. Be careful not to get any anti-seize on the brake pad

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 material or rotor.

IV. Before installing the brake caliper, It is very important to compress the brake
piston back down in order to account for the added pad depth created by the new
pads. Check service information on how your specific make and model’s brakes

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 are compressed.

V. Install the brake pads and brake pad guides. Be sure that the brake pads are
sitting evenly in the bracket. The brake caliper will be difficult to close if the pads
are misaligned.

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VI. Close the brake caliper over the pads and secure the caliper with the 2 bolts.

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VII. Reinstall wheel.

VIII. Torque wheel lugs to spec in a star pattern

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6.0 Conclusion
The final step to ensure the vehicle is ready is to lower the vehicle off the
jack and jack stands and torque the wheel lugs to specification. Lower the car by
lifting it with the jack until you are able to pull out the jack stands, then slowly let
the vehicle down from the jack. The most important and final step is to torque the wheel
lugs to proper specification in a star pattern.

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