Front Brake Pad Replacement

Replace front brake pads on a 2009 Aston Martin DB9, including caliper removal, pad installation, and system verification.

Warnings

Tools required

Parts

• Front brake pad set (left and right) × 1 — Use OEM specification or equivalent ceramic/low-metallic pads
• Brake pad anti-squeal shims (if not included with pads) × 1 — Often included with OEM pad sets
• Brake pad wear sensors (if equipped and being replaced) × 2 — Verify sensor presence before ordering

Fluids

• DOT 4 low-viscosity brake fluid — 0.25 qt

Preparation

1. Park vehicle on level, stable ground. Engage parking brake and place transmission in Park.
2. Open hood and locate brake fluid reservoir. Check fluid level and remove small amount with turkey baster if reservoir is near MAX line to accommodate fluid displaced by piston compression.
3. Loosen front wheel lug nuts 1/4 turn while wheels are on ground.
4. Raise front of vehicle with floor jack using manufacturer-specified jacking points (refer to owner's manual for chassis jack point locations).
5. Support vehicle securely on jack stands placed at manufacturer-approved support points. Never rely solely on hydraulic jack.
6. Remove front wheels completely and set aside.

Procedure

1. 1

   Inspect brake system and prepare work area
   With wheel removed, visually inspect brake rotor for excessive scoring, cracking, or heat discoloration. Check brake hose for cracks, bulging, or fluid leakage. Measure rotor thickness with micrometer if available and compare to minimum specification (typically stamped on rotor hat). If rotor damage is present or thickness is below minimum, rotor replacement is required before proceeding. Spray brake assembly with brake cleaner and wipe with clean rag to remove loose dust and debris.
2. 2

   Disconnect brake pad wear sensor (if equipped)
   Locate the brake pad wear sensor wire connector on the inboard pad (typically a small electrical connector near the caliper). Press release tab and disconnect the sensor connector. Carefully route the wire clear of the caliper to prevent damage during removal. Note the sensor wire routing for reinstallation.
3. 3

   Remove caliper slide pin bolts
   Identify the two caliper mounting bolts securing the fixed (opposed-piston) Brembo caliper to the hub carrier (upright). These are located on the inboard side of the caliper body. Using the appropriate hex/Allen or Torx bit as specified by Aston Martin, remove both upper and lower caliper mounting bolts only if full caliper removal is required. Set bolts aside and inspect threads for damage. (Verify bolt head type and size against Aston Martin service documentation before starting.) Note: This platform uses a fixed (opposed-piston) front caliper that does NOT have slide pins. Do not attempt to remove slide pin bolts. Instead, identify the pad retaining pins/clips (or anti-rattle spring) securing the pads in the caliper. Remove the retaining clip and withdraw the pad retaining pin(s) so the pads can be extracted through the caliper opening. Verify the caliper-to-hub-carrier mounting bolt torque specification from factory documentation before any caliper removal. Note: Hex/Allen bit socket set (verify exact size against factory documentation; caliper mounting bolts are typically large hex socket head) Note: Identify the two caliper mounting bolts securing the fixed Brembo caliper to the hub carrier. Verify the exact bolt head type and size against factory documentation before use. Remove both caliper mounting bolts and set aside, inspecting threads for damage.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
4. 4

   Remove brake caliper
   Carefully lift the caliper straight off the rotor after removing both mounting bolts. Do not allow the caliper to hang by the brake hose. Support the caliper using wire or a bungee cord attached to the suspension or chassis, ensuring no tension is placed on the brake line. The caliper should rest securely without stress on the hydraulic hose. Note: On this fixed-caliper design, the caliper does not pivot. Once the pad retaining pin(s) and clip are removed, the brake pads can be withdrawn directly from the caliper without removing the caliper body. If full caliper removal is necessary, unbolt the two caliper mounting bolts from the hub carrier and support the caliper with wire or a bungee cord so no tension is placed on the brake hose. Note: Carefully lift the fixed caliper straight off the rotor. Do not allow the caliper to hang by the brake hose. Support the caliper using wire or a bungee cord attached to the suspension or chassis, ensuring no tension is placed on the brake line. The caliper should rest securely without stress on the hydraulic hose.
5. 5

   Remove old brake pads and hardware
   Remove the pad retaining pin(s) and anti-rattle spring/clip, then slide the old brake pads out of the caliper body. Note the orientation and position of the inboard and outboard pads, as well as any anti-rattle clips, shims, or springs. Remove and inspect all pad hardware (anti-rattle clips and shims). If hardware is corroded, bent, or damaged, replace with new components. If reusing hardware, clean thoroughly with wire brush and brake cleaner. Note: Remove the pad retaining pin clips/cotter pins, withdraw the pad retaining pin(s), and lift out the anti-rattle spring. Remove the old brake pads from the caliper body. Note the orientation and position of the inboard and outboard pads and any hardware. Inspect all pad hardware; if corroded, bent, or damaged, replace with new components. If reusing hardware, clean thoroughly with wire brush and brake cleaner.
6. 6

   Inspect caliper bracket and slide pins
   With pads removed, inspect the caliper pad abutment surfaces and the pad retaining pin(s) and anti-rattle clip for corrosion, wear, or damage. Clean the pad contact surfaces thoroughly. Inspect the retaining pins for scoring or corrosion and replace if damaged. This fixed caliper has no slide pins or sliding bracket to service. Apply a thin film of appropriate anti-seize/brake grease only to the pad retaining pins and abutment edges before reassembly; do not grease piston faces or friction surfaces. Note: With pads removed, inspect the caliper body pad abutment surfaces for corrosion or damage. Use a wire brush to clean these surfaces thoroughly. Inspect the pad retaining pins and anti-rattle spring/clip for wear, scoring, or corrosion and replace if damaged. Inspect the caliper piston dust boots for cracking or leakage. Do not apply grease to pistons or friction surfaces. Note: With pads removed, inspect the caliper pad abutment surfaces and the pad retaining pin and anti-rattle spring for corrosion or damage. Use a wire brush to clean these surfaces thoroughly. Inspect the retaining pin for scoring or corrosion and replace if damaged. Do not apply grease to the piston faces or friction surfaces.
7. 7

   Compress caliper pistons
   Using a proper brake caliper piston spreader tool, slowly and evenly retract the opposed caliper pistons into their bores on both sides of the caliper. Avoid using a single-sided C-clamp, which can over-extend the opposing pistons. Position the tool so it contacts the piston face (or back of old pad if still in caliper) and the rear of the caliper body. Apply steady, gradual pressure. Watch the brake fluid reservoir under the hood and ensure it does not overflow as fluid is displaced. If fluid level rises excessively, remove additional fluid from reservoir. Compress pistons until fully retracted and flush with caliper bore. Note: Using a pad-spreader tool, push the opposed pistons back evenly into their bores. Retract the pistons on both sides of the caliper gradually and evenly, keeping all pistons retracted together to avoid one side popping out as the other is pushed in. Do not use a single C-clamp against the caliper body.
8. 8

   Install new brake pad hardware and pads
   Install new or cleaned anti-rattle spring/clips. Apply a thin layer of appropriate anti-squeal/brake grease to the pad backing plate contact points only, avoiding any grease contact with friction material or rotor. Install the new brake pads into the caliper body, then install the pad retaining pin(s) and anti-rattle spring, verifying wear sensor placement per the vehicle's original configuration.pped) is positioned on the inboard side. Verify pads are seated correctly in the bracket and move freely. Note: Install the new brake pads into the caliper body, ensuring correct inboard/outboard orientation and that the pad with the wear sensor (if equipped) is on the correct side. Fit the anti-rattle spring and insert the pad retaining pin(s), securing with new clips/cotter pins. Apply a thin layer of silicone brake grease only to pad abutment/backing plate edges, avoiding any contact with friction material or rotor.
9. 9

   Reinstall brake caliper
   Remove the wire or bungee cord supporting the caliper. Carefully lower the caliper straight over the rotor and new brake pads, and align the caliper mounting bolt holes with the threaded holes in the steering knuckle. Ensure the caliper body does not pinch or damage the brake hose during positioning. Verify pads remain properly seated as caliper is lowered into place. Note: Carefully position the fixed caliper over the rotor and new brake pads and align the caliper mounting bolt holes with the hub carrier.
   Torque spec

   Caliper Slide Pin Bolts35 Nm (26 lb-ft)
10. 10

    Install and torque caliper slide pin bolts
    Apply threadlocker (per Aston Martin specification) to the caliper mounting bolt threads. Insert both upper and lower mounting bolts and thread by hand to avoid cross-threading. Using a torque wrench, tighten both caliper mounting bolts to the Aston Martin-specified torque (verify exact value in factory service documentation — these are large structural fasteners typically well above 90 Nm, not 35 Nm) in an alternating pattern to ensure even seating. Note: If the caliper was unbolted from the hub carrier, reinstall the caliper mounting bolts with the manufacturer-specified threadlocker (do not grease the threads) and torque to the factory specification, which must be verified from Aston Martin service documentation (caliper mounting bolts on this platform are high-torque and typically require a value well above 35 Nm). If only the pads were removed via the retaining pins, no caliper bolts need to be torqued. Note: Using a torque wrench, tighten the caliper mounting bolts to the factory-specified value for this fixed caliper (verify against Aston Martin workshop documentation — this is a large structural fastener, typically well above 90 Nm, not 35 Nm). Apply threadlocker if specified by the factory procedure. Note: Apply medium-strength threadlocker to the caliper mounting bolt threads if specified by the factory procedure; do not apply grease to the bolt threads.
    Torque spec

    Caliper Slide Pin Bolts35 Nm (26 lb-ft)
11. 11

    Reconnect brake pad wear sensor
    Reconnect the brake pad wear sensor electrical connector (if equipped) by aligning the connector halves and pressing together until the locking tab clicks into place. Route the sensor wire as noted during removal, ensuring it does not contact rotating components, suspension parts, or sharp edges. Verify the wire has adequate slack for suspension travel.
12. 12

    Repeat procedure for opposite side
    Perform steps 1 through 11 on the opposite front wheel to replace the second set of brake pads. Both front brake pads must be replaced as a pair to ensure even braking performance.
13. 13

    Reinstall wheels and lower vehicle
    Position the front wheels onto the hubs, aligning the wheel bolt holes with the hub threads. Install all wheel bolts by hand, threading them in a star/criss-cross pattern to center the wheel. Snug the wheel bolts with a wrench but do not fully torque while vehicle is on jack stands. Carefully raise vehicle slightly with floor jack, remove jack stands, and lower vehicle completely to the ground. With full vehicle weight on wheels, use a torque wrench to tighten the wheel bolts to the Aston Martin-specified torque (verify exact value in factory service documentation — the assumed 89 Nm value is too low and the correct figure is substantially higher) in a star/criss-cross pattern (tighten opposite bolts in sequence, not adjacent bolts). Note: With full vehicle weight on wheels, use a torque wrench to tighten the wheel bolts to the Aston Martin-specified torque (verify exact value in factory service documentation — the assumed 89 Nm value is likely too low) in a star pattern (tighten opposite bolts in sequence, not adjacent bolts). Note: With full vehicle weight on wheels, use a torque wrench to tighten the wheel bolts to the factory specification (approximately 150 Nm / 111 lb-ft — verify against Aston Martin documentation) in a star pattern (tighten opposite bolts in sequence, not adjacent bolts).
    Torque spec

    Wheel Lug Nuts89 Nm (66 lb-ft)
14. 14

    Restore brake pedal pressure
    Before moving the vehicle, sit in the driver's seat and pump the brake pedal slowly and firmly multiple times (typically 10-15 pumps) until a firm, consistent pedal feel is achieved. This repositions the caliper pistons against the new pads. The first few pumps will feel soft as pistons extend. Check the brake fluid reservoir and top off to the MAX line with fresh brake fluid of the Aston Martin-specified type (verify exact DOT 4 specification in the owner's manual before topping off) if necessary. Do not overfill.

Reassembly

1. Wheel installation mirrors removal: mount wheel, install lug nuts by hand in star pattern, snug while on stands, final torque to 89 Nm (66 lb-ft) in star pattern after lowering to ground.
2. Verify brake pedal is firm before attempting to move vehicle. If pedal remains soft after pumping, check for air in system or incomplete piston extension.
3. Check brake fluid level in reservoir and adjust to MAX line with DOT 4 low-viscosity brake fluid.

Verification

• With engine off, pump brake pedal 10-15 times and verify firm, consistent pedal feel. Pedal should not sink slowly to floor.
• Check brake fluid reservoir level is between MIN and MAX marks. Top off if necessary with DOT 4 low-viscosity brake fluid.
• Visually inspect all work areas for tools or parts left behind. Verify no wires, hoses, or components are pinched or improperly routed.
• Perform low-speed test drive in safe area (parking lot or quiet street). Test brakes at 5-10 mph to verify proper engagement. Brakes should engage smoothly without pulling to one side.
• After test drive, inspect wheel areas for fluid leaks, unusual odors (overheating), or smoke.
• Perform gradual brake bedding-in procedure: avoid hard stops for first 200 miles. Make 20-30 gentle stops from 30-40 mph to gradually heat-cycle the pads and transfer material to rotors.

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