15/10/2009
When it comes to vehicle safety, few components are as critical as your brakes. For Ford Falcon owners, ensuring your braking system is in top condition isn't just about compliance; it's about confidence, control, and peace of mind on the road. Whether you're seeking straightforward replacement pads or contemplating a significant performance upgrade, understanding the options available for your Falcon is paramount. This guide delves into everything you need to know, from where to source quality parts to the intricacies of advanced braking solutions like the acclaimed PBR upgrade.
Where Can I Purchase Disc Brake Pads for My Ford Falcon?
Finding the right disc brake pads for your Ford Falcon is a crucial first step in maintaining its safety and performance. Fortunately, there are several reliable avenues available to acquire these essential components, catering to various preferences and budgets.
Online Automotive Retailers
The digital marketplace offers a vast selection of brake pads from numerous manufacturers. Reputable online automotive parts stores provide convenient browsing, detailed product descriptions, and often competitive pricing. When purchasing online, it's vital to accurately specify your Falcon's model year, series (e.g., BA, BF, FG), and engine type to ensure compatibility. Many sites feature vehicle fitment tools that guide you to the correct parts. Look for retailers that offer clear return policies and customer reviews to gauge product quality and service.
Local Auto Parts Stores
For those who prefer a hands-on approach or require immediate assistance, visiting a local auto parts store is an excellent option. Staff can often help identify the correct brake pads for your specific Falcon model and provide advice on different brands and types (e.g., ceramic, semi-metallic). This option allows for direct inspection of the product and eliminates shipping delays, which can be particularly useful if you're undertaking a last-minute repair.
Ford dealerships are a reliable source for genuine Original Equipment (OE) brake pads specifically designed for your Falcon. While potentially pricier than aftermarket alternatives, OE parts guarantee perfect fitment and performance as intended by the manufacturer. This is often the preferred choice for those who wish to maintain their vehicle with factory-standard components, ensuring optimal compatibility with other original braking system elements.
Specialist Performance Shops
If you're looking to upgrade your Falcon's braking performance beyond standard specifications, specialist performance automotive shops are invaluable. These establishments often stock high-performance brake pads and complete brake kits from renowned aftermarket brands. Their knowledgeable staff can offer expert advice tailored to your driving style and vehicle modifications, helping you select pads that offer enhanced friction, fade resistance, and durability for spirited driving or track use.
How Do Brake Pads Work on a Ford Falcon?
The braking system on your Ford Falcon, like most modern vehicles, relies on the principle of friction to convert kinetic energy (the motion of the car) into thermal energy (heat), thereby slowing and stopping the vehicle. At the heart of this process are the disc brake pads.
When you press the brake pedal, hydraulic fluid is pushed through the brake lines to the calipers. The calipers, which are mounted over the brake rotors (or discs), contain pistons that are forced outwards by the hydraulic pressure. These pistons then press the brake pads against the spinning rotors.
The brake pads themselves are made from a friction material bonded to a steel backing plate. As the pads clamp down on the rotating rotors, the friction between the two surfaces generates immense heat and resistance, which rapidly slows the rotation of the wheels and, consequently, the vehicle. The design of the rotors, often featuring internal vanes, helps to dissipate this heat efficiently, preventing overheating and maintaining braking performance.
Over time, the friction material on the pads wears down due to this constant process. This wear is a normal part of operation, but it means that brake pads are consumable items that require periodic replacement to maintain effective braking. Signs of wear include squealing noises, reduced braking efficiency, or a grinding sensation, indicating that the pads are nearing the end of their lifespan.
Understanding the PBR Brake Upgrade for BA Falcons
For owners of BA Ford Falcons who have invested in power-up modifications or simply desire superior stopping power, the standard braking system can sometimes feel inadequate. This is where the PBR brake upgrade (part number PK5-9) steps in, offering a comprehensive solution that mirrors the performance of Ford's premium brake option and even some FPV GT and Pursuit Performance Brakes.
The Essence of the PBR Upgrade
The PBR BA Falcon Upgrade is not just a pad swap; it's a complete system overhaul designed to significantly enhance braking performance, feel, and durability. This kit replaces key components of both the front and rear braking systems with high-performance equivalents.
Front Brake Enhancements
At the front, the upgrade introduces substantial improvements:
- Rossini Grooved Rotors: These new rotors measure a generous 325mm x 32mm, a significant increase over the standard 298mm x 28mm rotors. The external faces feature six straight grooves, specifically designed to expel hot gases generated between the rotor and pad during braking. This mechanism is crucial for improving brake efficiency and maintaining a consistent pedal feel, especially under heavy use.
- Pillar-Style Internal Venting: Utilising technology licensed from Brembo, the front rotors incorporate pillar-style internal venting. PBR asserts that this design "aggressively sucks in and expels cooling air through the rotor," further enhancing heat dissipation and preventing brake fade.
- C6 Twin-Pot Calipers: The kit includes PBR's robust C6 twin-pot calipers. These calipers boast a very rigid design and employ twin 40.5mm pistons. The large diameter of these dual pistons ensures the caliper remains perfectly square to the rotor during hard brake applications. This design promotes even pad wear across the entire surface and ensures maximum pad contact, optimising braking force. The calipers are finished in a durable, high-temperature and brake fluid-resistant red enamel, providing both performance and aesthetic appeal.
Rear Brake Enhancements
The PBR upgrade extends to the rear of the vehicle, replacing the standard rotors and calipers:
- Grooved Solid Rear Discs: While maintaining the standard size of 303mm x 16mm, the new rear discs come with cooling grooves on their external faces. These grooves, similar to the front, aid in heat dissipation and gas expulsion.
- Single-Piston Calipers: The rear calipers are essentially the same as the original parts in design, featuring a single 40.5mm piston, but are coated in the same striking red enamel as the front calipers, ensuring a consistent look.
Enhanced Brake Pads and Hoses
The supplied brake pads are a significant upgrade, offering greater friction and superior high-temperature stability compared to standard Falcon pads. The design of the new C6 front calipers also allows for the fitment of larger pads, increasing the front pad swept area from 71 to 73.2cm². Furthermore, the PBR upgrade includes street-legal braided stainless steel brake hoses, which offer reduced expansion under pressure compared to traditional rubber hoses, leading to a firmer and more consistent brake pedal feel.
While the PBR kit is remarkably similar to the Ford Premium Brake option and FPV Performance Brake system, there are a few notable distinctions:
- Brake Hoses: The PBR kit comes standard with braided stainless hoses, whereas Ford and FPV vehicles typically use low-expansion rubber hoses. Only the top-tier Brembo-equipped FPVs feature factory braided hoses.
- Cooling Groove Pattern: The PBR rotors utilise a distinct pattern of six straight grooves, differing from the twin-circle grooves found on Ford/FPV products.
- Caliper Aesthetics: PBR calipers are enamelled in red, providing a bold visual statement, while FPV parts are typically blue with an FPV logo.
Fitment and Installation
The PBR BA brake upgrade is compatible with any BA Falcon, but it's crucial that the vehicle is fitted with 17-inch or larger wheels. Some 17-inch wheels may still not provide sufficient clearance for the larger C6 front calipers. To avoid disappointment, PBR offers a "Wheelcheck" template on their performance website, which allows you to verify clearance before making a purchase.
Installation of the kit is surprisingly straightforward and can typically be completed within a couple of hours by a competent mechanic or experienced DIY enthusiast. The process involves:
- Front: Disconnecting and blocking the standard brake hose at the master cylinder, removing the old caliper and rotor, cleaning the hub surface, installing the new rotor, and finally, fitting the new calipers and braided hose using new support brackets, washers, and banjo bolts.
- Rear: A similar process to the front, with the added step of removing the standard brake hose support bracket by drilling out a rivet and then riveting a replacement bracket into position.
The final, critical steps involve bleeding the brakes to remove any air from the hydraulic system and then properly "bedding-in" the new pads. Bedding-in is essential to optimise performance and longevity by transferring a thin layer of friction material to the rotor surface.
Real-World Performance Results
Road tests, such as those conducted by AutoSpeed on a Jim Mock Motorsport BA Falcon equipped with the PBR upgrade, have consistently demonstrated impressive results. The new brake system maintains virtually standard brake pedal pressure, meaning the car's feel remains familiar. However, under hard brake applications, the vehicle exhibits powerful and balanced stopping without any bias problems. Crucially, repeated hard brake applications showed no signs of fade, and brake pedal feel remained excellent throughout, highlighting the system's superior heat management and consistency.
Cost and Value Proposition
While an investment, the PBR BA Falcon brake upgrade offers compelling value. Jim Mock Motorsport, for instance, has charged approximately AUD$2800 for supply and fitment. This price point is notably AUD$150 cheaper than Ford's Premium Brake option, which offers an almost identical performance profile. When factoring in this monetary saving and the inclusion of high-quality braided steel hoses, the PBR BA Falcon brake kit presents itself as a very attractive and worthwhile upgrade for any Falcon owner serious about their vehicle's stopping capabilities.
Comparison: Standard BA Falcon Brakes vs. PBR Upgrade
To further illustrate the advantages, here’s a comparison table highlighting the key differences between the standard BA Falcon braking system and the PBR upgrade:
| Feature | Standard BA Falcon Brakes | PBR BA Falcon Upgrade (PK5-9) |
|---|---|---|
| Front Rotor Size | 298mm x 28mm | 325mm x 32mm (Grooved Rossini) |
| Front Rotor Venting | Standard internal venting | Pillar-style internal venting (Brembo licence) |
| Front Calipers | Single-pot | C6 Twin-pot (twin 40.5mm pistons) |
| Rear Rotor Size | 303mm x 16mm | 303mm x 16mm (Grooved solid) |
| Rear Calipers | Single-pot (standard) | Single-pot (40.5mm piston, red enamel) |
| Brake Pads | Standard Falcon pads | Greater friction, high-temperature stability |
| Brake Hoses | Low expansion rubber hoses | Braided stainless steel hoses |
| Caliper Finish | Unspecified/Standard | High-temperature red enamel |
| Minimum Wheel Size | Standard | 17-inch or larger (with clearance check) |
Frequently Asked Questions About Ford Falcon Brakes
How often should I replace my Ford Falcon brake pads?
The lifespan of brake pads varies significantly depending on your driving style, road conditions, and the type of pads used. Generally, brake pads can last anywhere from 30,000 to 70,000 miles. Aggressive driving, frequent stop-and-go traffic, and heavy loads will accelerate wear. It's advisable to have your brakes inspected during every service or at least annually to assess their condition.
What are the common signs that my brake pads need replacing?
Look out for these tell-tale signs: a high-pitched squealing sound when braking (often caused by wear indicators), a deep grinding or metallic noise (indicating severe wear where the metal backing plate is contacting the rotor), a longer stopping distance, a vibrating brake pedal, or the car pulling to one side when braking. If your brake warning light illuminates on the dashboard, it's also a clear sign to get them checked immediately.
What is "bedding-in" new brake pads, and why is it important?
Bedding-in (also known as 'burnishing' or 'seating') is a crucial process performed after installing new brake pads and rotors. It involves a series of controlled stops to gradually bring the brake components up to temperature. This process transfers a thin, even layer of friction material from the pads onto the rotor surface, ensuring optimal performance, reducing noise, and extending the lifespan of both the pads and rotors. Skipping this step can lead to reduced braking efficiency, uneven wear, and noise issues.
Are performance brake pads worth the investment for a daily driver?
For a standard daily driver, high-performance pads might be overkill. However, if you frequently carry heavy loads, tow, drive in mountainous terrain, or have made performance modifications to your Falcon (like increased engine power), upgrading to better quality or performance-oriented pads can significantly enhance safety and driving confidence by offering improved fade resistance and consistent stopping power. The PBR upgrade, for example, is particularly beneficial for modified BA Falcons.
Can I replace my Ford Falcon brake pads myself?
While replacing brake pads is a common DIY task, it requires mechanical aptitude, the correct tools, and adherence to strict safety procedures. You'll need jack stands, a torque wrench, a C-clamp or brake caliper piston tool, and potentially a brake bleeding kit. If you're not confident, or if your Falcon has complex braking systems (like the PBR upgrade), it's always safer to consult a qualified mechanic to ensure the job is done correctly and safely.
Conclusion
Maintaining your Ford Falcon's braking system is non-negotiable for safe and confident driving. Whether you're simply replacing worn-out pads or considering a significant performance upgrade like the PBR kit, understanding your options and the mechanics behind them empowers you to make informed decisions. The PBR BA Falcon brake upgrade stands out as an exceptional value proposition, offering superior stopping power, enhanced durability, and a more responsive pedal feel for those seeking to unlock their vehicle's full potential. Always prioritise quality components and proper installation to ensure your Falcon continues to perform safely and reliably on every journey.
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