Ferodo Front Pad Replacement in Brembo Issue (or Lack of Confidence)

[freelancer2011]

Hi,

I’m pretty sure this is just confidence building required. It’s my first time replacing the pads. I’ve used the below video as a reference:
http://www.youtube.com/watch?v=17oO6Xp5ej0

When I put the new Ferodos in, there’s only 1 mm gap (see attached). I can’t see how I can pop that around a brake disc at the moment.

Details are:
Ferodo Platinum Front – FDB2006P – 4mm of frictional material on each pad. So, that’s 8mm.
Current Disc: OEM and at 4.49mm
Brembo calliper but don’t know what model it is.
2008 F650 GS Twin. No recalls outstanding according to the dealer

After removing the calliper from the legs, I’ve noticed I can expand it wider like an accordion, as per video. Should I put a spanner in they’re first like the video and see if I can wedge it any wider? It *feels* like that’s as far as it will stretch but I’m not sure.

If that doesn’t work, should I put in just half of the new pair in first, let that wear in and then pop in the second new one when the first half of the pair has worn in a bit first?

Is there a chance the Brembo calliper is damaged/defective and doesn’t open up fully? I’ve noticed the REAR Brembo, pads and its’ frictional material are can all be seen clearly. Whilst on the front, it’s always looked like a tight fit and difficult to see.

Any help would be gratefully appreciated.
Lab.

 

[MikeO]

This is one of your caliper pistons. Gently ease them back into the caliper - by levering apart the pads, or by removing the pads and using a piece of wood - and you'll be able to refit your caliper with your new pads...

Mike

 

[Fanum]

Your pistons haven't been pushed back.

You can use a screwdriver (with a metal plate to avoid scoring the crown of the piston) or a G clamp around the outside of the caliper, then wind it up and compress the piston, or any sensible sort of levering to push the pistons back in to the caliper body.

Remove the cap from the brake fluid reservoir and keep an eye on the level........it's unlikely to overflow but the pistons will be full of it and you're pushing it back through.

They should go back far enough to give you an easy fit over the disc surfaces....they may touch, but they'll go.

 

[freelancer2011]

Thanks so much, Mike! I feel extremely embarrassed! I'll give it a shot, tomorrow morning :O)

 

[freelancer2011]

And you, too, Fanum

 

[JohnnyBoxer]

When I put the new Ferodos in, there’s only 1 mm gap (see attached). I can’t see how I can pop that around a brake disc at the moment.

If that doesn’t work, should I put in just half of the new pair in first, let that wear in and then pop in the second new one when the first half of the pair has worn in a bit first?

Lab.

I would do that, or sand them down

Sorry Lab couldn't resist - PMSL

As Mike says, push a screwdriver GENTLY between the pads and push the calipers back SLOWLY

If the don't go back far enough, you may have to remove a bit of brake fluid (by syringe) from the front brake master cylinder

BUT, once fitted and bolted up - (remember to torque up those caliper bolts to the fork leg) - make sure there is the correct amount of brake fluid (to the level) in the front master cylinder

 

[Fanum]

I feel extremely embarrassed! I'll give it a shot, tomorrow morning :O)

No need to be embaressed.....you're doing it and learning as you go

Better to ask a genuine question, take a ribbing and get it right than fekk it up or give up and have a dealer do it forever

 

[Steptoe]

You should push the pistons back with the old pads installed, especially as it's your firts time. That way it won't matter if you gouge any lumps out of the friction material.
When the pistons are pushed fully back then insert the new pads.

Now i'll tell you the easiest way to do it - with that type of caliper the easiest thing to do is refit the old pads ( no need to insert the pad pin fully. Drop the caliper back in place on the fork leg and over the disc, then with your foot press against the caliper bady. The pads and caliper will work together to push the pistons back into the caliper.

Remember this for the next time you change the pads, that way you can push/retract the pistons back into the caliper before you undo the caliper/knock out the retaining etc etc. That also works with the rear caliper

 

[freelancer2011]

Thanks Steptoe and everybody for their support for what should have been a relatively straight-forward job!

I was going to attempt it again today and getting a syringe (just in case there's a lot of brake fluid that does overflow). If I told you guys the bike just came back from its' 12k service (which did include brake fluid replacement) do you reckon there is a high chance the calipers would be filled with the stuff?

I was going to go into town to get some syringes but between Halfords, Maplins and Wilko not having any, and it being Sunday, I'm going to have to ring around/look online. Do you reckon a 50ml or 100ml syringe to have as backup would be good?

And, Farnum, any chance of me compromising the brake fluid by opening the top of the reservoir? Is the fluid hygroscopic?

Cheers,
Lab.
PS: If anything I am feeling happy to be attempting this myself rather than let the dealer do this :O) I think I annoyed the hell out of them by saying I'd like to do several stuff myself

 

[curiousexplorer]

clean first

A warning: before you push the pistons back, clean them first to remove any sand or grit that may damage the seals of the pistons. I just use a squirt of brake cleaner, and a toothbrush (old one!) Good luck, you probably will notice an improvement in front brake...

 

[Greg Masters]

I have to say that it worries the crap out of me that people who clearly have little idea of what they are doing can 'service' brakes.

To do work like this requires a decent grasp of how the thing works and what you need to do to do the service but it also requires an appreciation of technique. Even if you know what you should be doing, if you act like a rock-ape, you're likely to damage something.

Of course, those of us who 'can and do' had to learn sometime, but it was normally under the watchful eye of someone else (for a safety critical system like brakes). If your inexperience or rock-ape technique has you stripping spark-plug threads or similar, then you learn the expensive way. With brakes you learn the hard way!

When I was in my 20s, I got summoned to an Inquest of someone who did the job themselves without decent safeguards .....



Greg

 

[JohnnyBoxer]

Must be some bods around London, to cast a 'watchful' eye over the chap, whilst he does it

 

[Greg Masters]

Must be some bods around London, to cast a 'watchful' eye over the chap, whilst he does it

Yes, and I'd be quite happy to do that (unless he lives sarf of the river )

Greg

 

[v8legend]

I have to say that it worries the crap out of me that people who clearly have little idea of what they are doing can 'service' brakes.

I have to admit, I had similar thoughts myself. I'm all for 'having a go', but the consequences of getting this wrong worry me. If the OP didn't realise that the pistons that push out and give you stopping power, also need pushing back to fit new pads, then maybe this task is behond him.

If freelancer doesn't take up Greg's offer of help, then he's welcome to pop round here. I am about 45 miles away though!

 

[freelancer2011]

A belated and well overdue THANKS TO ALL!!!!

I took on-board all your guys' advice and managed to get the new pads in without having to get any fluid removed from the reservoir. Plank of wood, the foot and gentle pressure sorted!!

Ta again!
Lab!!