Disc Brake Systems

As industry-recognised global braking specialists, we produce over 12 million brake discs every year for vehicle manufacturers and the independent aftermarket. TRW True Originals are just that: originals that are never just a copy of an existing model. We design and build everything from the ground up to meet the real world challenges your customers face, and because we never stop researching and developing new safety and performance features, you’ll always have access to the latest developments in braking technology to pass on to your customers.

Did you know that we pack all our brake discs in VCI (volatile corrosion inhibator) paper rather than coating them in oil or rust preventative? You just take them out of the box and get to work – no need to waste time cleaning it off before fitting.

To provide increased corrosion resistance and performance, our product developers devised a new industry concept: black painted brake discs. By coating parts of the disc in our specially formulated black paint, we create a unique surface that acts as a protective barrier against corrosion.

When we manufacture TRW True Originals, we control every detail of every part. Because we’re committed to producing the safest and highest quality brake discs, we use a carefully controlled mixture of raw materials to produce the finest grey cast iron. By undertaking this process, it means that we can be sure of the best possible casting for the best performance quality.

All our castings are made to tight tolerances using top-quality EN-GJL-150 or EN-GJL-200 cast iron material.

• Disc thickness variation (DTV) never exceeds 10µm
• Runout never exceeds 30µm
• The central hole is fixed at H8 norm

Castings are subject to stringent safety tests and controls before being released for machining. These close tolerances provide hassle-free fitting for you, and comfortable performance for your customer.

The TRW True Originals range includes brake discs with integrated bearings and ABS sensor rings. Using oil, worn or damaged bearings increases the risk of disc damage, so TRW True Originals brake discs are available ready-assembled with mounted wheel bearings. We also provide toothed and magnetic ABS sensor rings.

When we manufacture TRW True Originals, we control every detail of every part. Because we’re committed to producing the safest and highest quality brake discs, we use a carefully controlled mixture of raw materials to produce the finest grey cast iron. By undertaking this process, it means that we can be sure of the best possible casting for the best performance quality.

All our castings are made to tight tolerances using top-quality EN-GJL-150 or EN-GJL-200 cast iron material.

• Disc thickness variation (DTV) never exceeds 10µm
• Runout never exceeds 30µm
• The central hole is fixed at H8 norm

Castings are subject to stringent safety tests and controls before being released for machining. These close tolerances provide hassle-free fitting for you, and comfortable performance for your customer.

Because we’re committed to producing the safest and highest quality brake discs, a carefully controlled mixture of raw materials is used to produce the finest grey cast iron. Machining process quality isn’t enough – it has to be the best possible mix from the initial casting for the best end performance quality.

Our exhaustive tests ensure:

• High carbon content (the fluidity allows easier casting and machining, plus a low degree of shrinkage)
• Low melting temperature (1140°C- 1200°C)
• High wear resistance
• High thermal capacity
• High tensile and compressive strength, giving high levels of rigidity

The castings then undertake a variety of stringent tests and controls before being released for machining to ensure the highest levels of safety.

Due to the European CO2 regulation, a manufacturer will be required to ensure that the average emissions of all new cars it produces – and which are registered in the European Community – are at, or below, the permitted level of emissions for its vehicle type. This has shifted the automotive market into the era of ‘light weighting’ and increased R&D development to focus on the following key drivers:

• Weight reduction
• Fuel Economy and CO2 emissions
• Enhanced vehicle performance and handling

BMW and Mercedes-Benz have developed Semi Compound disc ranges for several models in their portfolio – and ZF Aftermarket has a range of high-performance two-piece Semi Compound brake discs, designed to enhance safety and performance and extend endurance levels in heavier, more powerful vehicles covering the BMW and Mercedes design.

We also offer a range of brake discs with integrated bearings, ABS sensor rings and fixing accessories. This makes life much easier when it comes to fitting, as these critical safety components are often damaged when replacing the disc. Using an old, worn or damaged bearing can also increase the risk of damage to the disc itself. TRW’s brake discs with mounted wheel bearings are assembled to ensure the correct pressing in of the bearing. We’ll deliver both toothed and magnetic ABS sensor rings, depending on what is required.

We make DTEC brake pads using a premium ceramic formulation that reduces rim surface dust by up to 45%, and our COTEC friction coating cuts the stopping distances on new brake pads by up to 7 metres*.

COTEC is the unique friction coating developed by TRW that significantly improves safety after brake pad replacement, improving the contact between the brake pad and disc to outperform both our major competitors and original equipment.

* Independently tested by RDW

We make the back plates of TRW True Originals brake pads from high quality steel, and powder-coat them to inhibit rust. We bond the robust back plate to the friction material using a unique adhesive compound that can withstand extremely high temperatures and shear strengths (we know, because we’ve tested them to extremes).

We heat the friction material to up to 700°C to carbonise the first 0.5 to 1.5mm of its surface, getting rid of any trapped gases and resins. This reduces the need for bedding in and enhances brake pad performance. It’s a more effective process than conventional brake pad scorching, and not all aftermarket suppliers will go this far – some don’t even carry out a scorching process at all.

The scorched plate layer is then given an innovative surface coating that optimises friction right from the first stop – your customers will feel the benefit of better braking as soon as they drive away from your workshop.

All TRW True Originals brake pads meet the strict ECE R90 specifications that apply to all aftermarket brands. But for us, the testing doesn’t end there, but continues in the lab, on the road and in between (for example, we carry out shear strength testing during production control). We test our brake pads to the extreme to meet industry standards. Then we test them harder, so that they meet TRW standards.

TRW True Originals brake pads are fitted with high quality shims that act as a damper on the backing plate – we use the same metal and rubber shim combination and special adhesive that’s used in original equipment.

Our brake pads and discs are tested in our NVH (noise vibration harshness) laboratories and on the road. This supports the noiseless function of brakes. To eliminate noise we use a glass fiber reinforced phenolic shims or in more noise sensitive applications stainless steel shims with different combination of damping materials. Only a specific combination ensures an NVH free brake system. TRW pads and discs to work quiet together.

All this product innovation and enhanced safety is matched with great service quality, too.

As braking specialists designing and building so much of the original equipment that vehicles are fitted with when they first roll out of the factory, our aftermarket expertise is unparalleled.

You and your customers benefit from the same OE quality whether you choose new or remanufactured brake calipers from TRW True Originals. We provide exceptional market coverage, easier fitting and direct-from-the-factory cutting edge innovations in braking safety and performance.

TRW True Originals gives you the convenience of buying a wide range of new and remanufactured products from the same source. Our remanufactured calipers carry the same guarantee as new ones, and reduce costs to your business and the environment.

By stripping, cleaning and rebuilding with OE quality parts, we can provide you with remanufactured brake calipers that perform just as well as those originally fitted to the car, 100% checked and end-of-line tested.

• Our sustainable supply chain for ageing parts helps you to avoid obsolescence issues
• Remanufacturing supports a reasonable price for low-volume parts in the market
• Remanufacturing uses just a fraction of the energy and CO2 required to make brand new calipers – saving over 1,500 tonnes of CO2 a year

• Every box contains the brake calipers plus all the accessories and instructions needed to fit fast and fit right
• TRW True Originals rear brake calipers are pre-filled with brake fluid, avoiding trapped air and making fitting much quicker and easier
• Because TRW manufactures every major part of the braking system, we can achieve the best design and integration of each component for easy, accurate fitting

TRW Universal Brake Caliper repair kit

An all-in-one solution that can fix up to 60 TRW brake calipers and 30 axles for longerlasting performance. Drive sustainability forward by reducing waste, with everything you need on-site – from guide bolts, bellows, and screws to dust caps and grease.

Click here to download our booklet for more information.

Our wide-ranging coverage of the vehicle parc means you spend less time searching for parts and more time where it matters most to your business. TRW True Originals give you more choice and excellent coverage to serve more customers: our rigorous manufacturing standards and dedicated support services back an impressive range that includes:

• New and remanufactured calipers
• Electric Park Brake Calipers (EPB) and Actuator Repair Kits
• Lightweight aluminium calipers, for improved fuel consumption
• Foundation brakes composite calipers (FBC), designed to the floating calipers concept, helping the braking system to run cooler and deliver enhanced stopping performance
• Painted calipers – matching the OE fitment when supplied as new
• Repair kits