Brake Disc Replacement

**Objective**: To provide a detailed and efficient procedure for replacing the brake discs, ensuring safety, precision, and adherence to manufacturer specifications.

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### Tools and Materials Needed:

- Jack and Jack stands

- Wheel chocks

- Lug wrench

- Torque wrench

- Socket set

- Brake cleaner

- Anti-seize lubricant

- Rubber mallet

- Wire brush

- Brake caliper tool

- New brake discs

- Safety glasses and gloves

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Step-by-Step Procedure

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### 1. Preparation (10 minutes)

1. **Ensure Safety (5 minutes)**

- **Explanation**: Wear safety glasses and gloves to protect against debris and chemicals.

- **Image**: Technician wearing PPE (safety glasses and gloves).

- **Safety Precautions**: Always wear PPE to prevent injury.

2. **Secure Vehicle (5 minutes)**

- **Explanation**: Place wheel chocks behind the rear wheels and engage the parking brake.

- **Image**: Wheel chocks placed behind the rear wheels.

- **Safety Precautions**: Ensure the vehicle is stable to prevent it from moving.

### 2. Lifting the Vehicle (10 minutes)

1. **Jack Up the Car (5 minutes)**

- **Explanation**: Use a jack to lift the car to the manufacturer-recommended lifting points and secure it on jack stands.

- **Image**: Jack lifting the car and the car secured on jack stands.

- **Safety Precautions**: Double-check the stability of the jack stands.

2. **Remove Wheels (5 minutes)**

- **Explanation**: Use a lug wrench to remove the wheel bolts and take off the wheels.

- **Image**: Wheel removed showing the brake assembly.

- **Safety Precautions**: Store the wheels safely to avoid tripping hazards.

### 3. Removing Old Brake Discs (30 minutes)

1. **Remove Caliper Bolts (10 minutes)**

- **Explanation**: Use a socket set to remove the caliper bolts. Support the caliper with a hanger to avoid stress on the brake line.

- **Image**: Caliper supported by a hanger.

- **Safety Precautions**: Do not let the caliper hang by the brake line.

2. **Remove Caliper and Bracket (10 minutes)**

- **Explanation**: Carefully remove the caliper and caliper bracket to access the brake disc.

- **Image**: Caliper and bracket removed from the brake disc.

- **Safety Precautions**: Ensure the caliper is securely supported.

3. **Remove Brake Disc (10 minutes)**

- **Explanation**: Remove any retaining screws and use a rubber mallet to gently tap the brake disc free if it's stuck.

- **Image**: Removing the brake disc with a rubber mallet.

- **Safety Precautions**: Use gentle taps to avoid damaging other components.

### 4. Installing New Brake Discs (30 minutes)

1. **Clean Hub Surface (5 minutes)**

- **Explanation**: Use a wire brush to clean the hub surface where the new disc will sit.

- **Image**: Cleaning the hub surface with a wire brush.

- **Safety Precautions**: Wear gloves to protect against sharp edges and debris.

2. **Install New Brake Disc (10 minutes)**

- **Explanation**: Place the new brake disc onto the hub and secure it with retaining screws.

- **Image**: New brake disc installed on the hub.

- **Safety Precautions**: Ensure the disc is properly aligned.

3. **Reattach Caliper and Bracket (10 minutes)**

- **Explanation**: Reattach the caliper bracket and the caliper over the new disc. Tighten the bolts to the manufacturer’s torque specifications.

- **Image**: Caliper and bracket reattached over the new disc.

- **Safety Precautions**: Use a torque wrench to ensure proper bolt tension.

4. **Apply Anti-Seize (5 minutes)**

- **Explanation**: Apply anti-seize lubricant to the caliper bolts and contact points.

- **Image**: Anti-seize being applied to the caliper bolts.

- **Safety Precautions**: Avoid getting lubricant on the brake disc surface.

### 5. Reassembling the Wheels (10 minutes)

1. **Install Wheels (5 minutes)**

- **Explanation**: Reattach the wheels and hand-tighten the lug nuts.

- **Image**: Wheels being reattached.

- **Safety Precautions**: Ensure all lug nuts are initially hand-tightened.

2. **Lower Vehicle (5 minutes)**

- **Explanation**: Lower the car from the jack stands and use a torque wrench to tighten the lug nuts to the manufacturer’s specifications.

- **Image**: Lowering the car and tightening the lug nuts with a torque wrench.

- **Safety Precautions**: Ensure the car is stable before fully lowering it.

### 6. Final Checks (10 minutes)

1. **Pump Brake Pedal (5 minutes)**

- **Explanation**: Pump the brake pedal to ensure the caliper pistons are properly seated.

- **Image**: Technician pumping the brake pedal.

- **Safety Precautions**: Do this before moving the vehicle to ensure brakes are functional.

2. **Test Drive (5 minutes)**

- **Explanation**: Conduct a low-speed test drive to check for proper brake function and to bed the new discs.

- **Image**: Technician performing a test drive.

- **Safety Precautions**: Conduct the test drive in a safe area to ensure the brakes are working correctly.

Total Time Required

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**1 hour 40 minutes**

Safety and Quality Assurance

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- **Double-check all bolts and components before concluding the job.**

- **Ensure proper disposal of old brake discs and any other waste materials.**

- **Always adhere to the manufacturer’s specifications for torque and part placement.**

By following this SOP, you ensure a safe, effective, and professional brake disc replacement.

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