Brake Maintenance Tips

Brake fluid replacement:

Replace brake fluid every 40K kms or 2 years, whichever is earlier or as per OEM schedule. During routine checks, if the brake fluid is dark or black in colour it is a sign of fluid contamination. Flush out old fluid and replace with TVS Sprinter brake fluid DOT 3, 4 or 4+.

Brake rotor skimming & replacement:

The service wear limit of a rotor is 2 mm only. If it exceeds this limit, replace with TVS Apache brake rotor along with a set of TVS Apache new brake pads for optimum performance. During every brake pad replacement, check the rotor condition and skim the rotor if there are score marks.

Caution after fitment of new brake pads:

New brake pads when fitted require a few stops to what is called “bed in”. To ensure optimum performance of your pads, avoid heavy braking for the first few kms (~50 kms).

Brake hose inspection:

When you replace brake fluid or the fluid level drops due to a leak in the brake system resulting in poor brake or no brake, check the rubber brake hoses for any rupture due to stone hit aging cracks etc. If there are any of these signs, replace with new TVS Girling brake hoses.

Brake fluid replacement:

Replace brake fluid every 40K kms or 2 years, whichever is earlier or as per OEM schedule. During routine checks, if the brake fluid is dark or black in colour it is a sign of fluid contamination. Flush out old fluid and replace with TVS Sprinter brake fluid DOT 3, 4 or 4+.

Brake pedal free play:

Check the brake pedal free play (~5mm). If zero free play is observed, then adjust the brake light switch. Zero free play may result in brake drag and consequent lining wear etc.

Brake adjustment – Drum brake:

Automatic adjustment takes more number of brake applications to adjust to the desired clearance after lining replacement. It is recommended to adjust the lining to drum clearance (~0.25 mm) manually for better pedal feel.

Brake rotor skimming & replacement – Disc brake:

The service wear limit of a rotor is 3 mm only. If it exceeds this limit, replace with TVS Apache brake rotor along with a set of TVS Apache new brake pads for optimum performance. During every brake pad replacement, check the rotor condition and skim the rotor if there are score marks.

Housing slide action – Disc brake:

During every brake pad replacement, move the brake housing backwards & forwards (before installing brake pads). In case any restriction is found, overhaul with kits.

Shoe return springs – S-cam brake:

Replace shoe return springs whenever linings are replaced, for effective braking.

Brake greasing- S-cam brake:

For better brake performance, it is recommended to do brake greasing every 30K kms or as per OEM schedule. Use appropriate greasing gun through the grease nipple provided in air chamber bracket till the grease oozes out near the slack adjuster.

Lining to brake drum gap – S-cam brake:

For effective braking, check the lining to brake drum gap. If uneven gap is observed, inspect auto slack adjuster and if necessary re-adjust the brakes as per manufacturer’s recommendation.

Spring – Dry brake:

Heat generation & corrosion are high in dry brakes compared to wet brakes. Thus, during the lining change, replace existing springs with TVS Girling new stainless steel springs for better brake performance.

Actuating disc replacement – Dry brake:

Actuating discs are packed & transported using rust preventive oil. Thus clean it with a dry clean cloth on either side of the disc, prior to fitting on the vehicle.

Friction disc replacement – Wet brake:

During friction disc replacement, the friction disc must be soaked for a minimum of one hour in the recommended grade of oil before fitment.

Brake adjustment:

To avoid vehicle pulling or ineffective braking etc, check the brake pedal free play and adjust the brakes as per manufacturer’s recommendation at frequent intervals.