Effective lubrication can be vital to the performance of a vehicle braking system, yet very often technicians fail to understand the importance of making the right choice. To provide practical advice on this issue, Head of Technical Training at TMD Friction, Scott Irwin, has provided some key information on the issues associated with copper greases and how considering the different lubricants available on the market can benefit mechanics.

Today more than ever the success of an independent garage is built on developing customer satisfaction and capturing repeat business. Having a dissatisfied customer returning with a noise or judder complaint, after brake replacement therefore needs to be avoided at all costs, especially when the system has been cleaned correctly and all necessary checks have been conducted.

Scott says that in garages, it’s not uncommon to see a tin of copper lubricant sitting open on a mechanic’s bench, exposed to the elements. Should contamination from dirt and moisture make their way into the tin, the lubricant will become ineffective, causing problems for the brakes if the contaminated grease was to be used within the braking system.

He comments, “There are several disadvantages of using a substance that contains copper. Firstly, copper greases can increase the likelihood of excessive run out when smeared on the surface of a hub, due to the potential contamination risks. The maximum run out should be 0.07MM which should always be tested with a DTI gauge.” He adds, “In addition to this, copper-based products cannot withstand high temperatures which stop the pads from moving freely, causing drag and premature wear. Copper can also react with steel and aluminium found within braking systems, increasing corrosion should contact occur. If you’ve ever had to knock the wheel off from the hub and wondered why, corrosion due to a copper-based lubricant could be the reason.”

Scott also points out that Copper-based greases are not environmentally friendly as the metal does not breakdown efficiently. Another key safety issue with copper grease is the effect it can have on a vehicle’s ABS, ESP and EPB systems. As copper is conductive, the presence of it can interfere with the magnetic sensors and this can cause the ABS to malfunction, causing problems with warning lights, or potentially cause wheel locking.

Scott recommends the use of metal-free greases, such as Mintex Cera Tec which offers many advantages. Cera Tec can withstand the braking system’s high temperatures and allows the pads to move freely, eliminating issues such as drag and wear. As the grease is non-conductive and doesn’t contain metal it can also be used without impacting on braking system electronics. One tube of Cera Tec caters for up to 35 sets of brake pads and protects against scratching and corrosion, offering a cost-effective solution to garages.

Scott concludes “Times and technology have moved on. It’s imperative that mechanics understand the risks associated with using a copper grease and research the best lubricant for the job.”