Ford Focus Brake Disc / Pad Replacement

Brakes arrived this morning, so I set about fitting them. They weigh as much as a small planet, I suspect they may contain small black holes to aid with the cooling.

Right, here is the original brake setup with some nice surface rust of the disc.


First job is to remove the bolts that hold the caliper to the hub. These require a T45 torx bit and a bit of elbow grease.


With the two bolts loosened, it is time to unclip the front pad from the caliper. This will require a pair of pliers.


With the front pad loose and the caliper bolts removed, try to remove the caliper. This is difficult because the worn disc has a lip of rust around the edge. After a bit of hassle, the caliper comes loose and must be suspended so that it does not strain the brake hose. Some discs are held onto the hub with a screw. Mine wasn't so it pulled straight off.


The pads can now be removed. The front one will slide out, the rear pad will unclip from the piston. Now the piston must be pushed back because the new disc and pads will require extra clearance.


Next job is to properly clean the hub and caliper. Using a combination of brake cleaner fluid and a wire brush, I scrubbed up the area as best I could.


Now get the copper grease out and cover the hub and any areas that will be in contact with the brake pads.


Here is a close-up showing the rails the pads run along. These must be greased up too.


Now get the rear brake pad and apply copper grease to any surface you think might be in contact with the caliper. Obviously keep the grease away from the friction surface.


Here you can see I greased the section that will run along the caliper rails. I'm sure rail is the wrong term but I don't care.


Once the rear pad has been clipped in place, grease up the front pad and install. This was quite tricky because the retaining wire was quite stiff.


Now turn your attention to the discs. These came with a layer of oil on them, presumably to inhibit them from corrosion. This must be cleaned off both sides prior to installation using brake cleaning fluid.


Now get the copper grease again and apply it to the surface that will mate onto the hub. This will aid removal in the future.


Then offer the disc up to the car and secure in place with a couple of wheel nuts.


Now offer the caliper up to the disc being careful not to let any copper grease to make contact with the disc surface.


Here is a photo from the side. Spanking clean!


Finally, apply copper grease to the front of the disc on the area that mates with the wheel. If any copper grease makes its way onto the threads, that is no bad thing. I'm beginning to wonder if I should buy shares in a copper grease company....


And that is that! Before test driving, push the brake pedal a few times to move the caliper piston to its operating position. Also, ensure that the brake fluid level is not too high or too low.

Having taken the car for a gentle test drive, the brakes work as I would expect. I have not used them in anger because they need to bed in first. I take it as a good sign that they work though.