What garages need to know about EV brake maintenance

From hybrid, plug-in hybrid, to battery electric vehicles, EVs are being adopted globally and will continue to increase in popularity. As the proportion of EVs on our streets grows, it’s important for workshops to understand the differences when it comes to maintaining the brake system.

TMD Friction, a global leader in brake friction manufacturing, explores the unique characteristics of electric drivetrains, how they differ from their internal combustion engine (ICE) counterparts, and what this means for brake maintenance.

Scott Irwin, head of technical training at TMD Friction, shares his top tips for EV brake maintenance.

Regenerative braking: less wear, more corrosion
EVs utilise regenerative braking, a technology that converts kinetic energy into electrical energy whilst decelerating or coming to a stop. Instead of being dissipated as heat, this energy is then used to charge the battery.

While this so-called motor brake is used for gentle deceleration or braking at low speeds, EVs are also still equipped with a powerful friction brake, which is used when braking at high speeds or performing an emergency stop.

This innovative dual braking system is a key difference between an EV and internal combustion engine (ICE) vehicle that workshops need to understand when it comes to maintaining the brakes. While regenerative braking enhances the vehicle’s efficiency, it reduces the demand on the conventional friction brakes. This means the brake pads and discs will experience less wear in an EV – but it does not mean they are immune to the effects of time.

Passenger car brake discs are made of grey cast iron, meaning they are susceptible to corrosion when exposed to environmental conditions such as moisture or salt. With normal usage, the friction surface of the brake pad “cleans” this thin layer of rust when the friction brakes are applied. But when they’re not used over a long period of time, the brake discs can accumulate rust.

Correct maintenance for EV brakes
Regenerative braking is not reducing the need for a traditional brake servicing, but it is changing the way workshops carry out their daily work. Rusted brake components can seize due to inactivity, which can affect braking performance. Because of this, a qualified technician should inspect an EV’s brake disc to identify signs of corrosion and check the thickness at regular service intervals.

If a disc is heavily corroded, or the disc thickness falls below the manufacturer’s specifications, they should be replaced immediately. In addition, the car owner should ask the driver about any unusual noises, vibrations, or changes in braking performance, as these could indicate issues with the brake pads and discs issues that require immediate attention.

Compared to in the past, brake servicing is moving away from more straightforward, wear-based replacement to a more comprehensive, inspection-based process. In the future, it may no longer be wear, but aging, that becomes the primary trigger for brake pad replacement.

Change the brake fluid every 18 months
Brake fluid deteriorates over time independently from the distance travelled. Conventional brake fluids are hygroscopic, meaning they attract and absorb moisture from the atmosphere. Even though brake fluid is in a “sealed” brake system, water vapour molecules can slowly penetrate the flexible rubber brake hoses or other rubber components in the brake system.

Over time, this results in an increase in the volume of moisture in the brake fluid, which results in a decline in the boiling point and an increased risk of corrosion to metal components. When the brake fluid boiling point reaches a critical level where it is dangerous, it will need to be replaced.

Textar brake fluid boil testers and other tools. Always follow the vehicle manufacturer’s recommendation on when to change the brake fluid. If no recommendation is given, for optimum safety the brake fluid should be changed every 18 months.

Not all brake fluids are alike
Regenerative braking in electric vehicles also means different demands on the vehicle’s brake fluid. The braking system is used less and is therefore subject to a lower load. The brake fluid must consequently be able to last longer.

Furthermore, electric cars are heavier than their combustion-engine counterparts due to their large battery packs, which means the mass to be decelerated is higher, leading to higher temperatures. This means technicians should choose a brake fluid with a high boiling point and a very good viscosity index.

For electric cars, TMD Friction recommends a brake fluid with a high boiling point and a very good viscosity index, such as Textar 5.1 Ultimate.

Tyre maintenance is key
Efficient tyre maintenance is essential for overall vehicle safety, including effective braking performance. Electric vehicles are typically heavier than ICEs and their tyres are therefore subject to more pressure during everyday journeys. Ensure your customers are aware of this and check that their tyres are correctly inflated. While you’re at it, also make sure they have sufficient tread depth – the minimum tread is 1.6mm in Europe. Speak to your local TMD Friction technical expert to learn about the specific requirements in your country.

Worn-out or underinflated tyres experience reduced traction between the tyre and the road surface. This can have a negative effect on braking performance, especially during emergency stops. Regularly inspect the tyres for signs of uneven wear and rotate them as recommended by the manufacturer.

Training is vital
As of 2025, only 26 per cent of UK automotive technicians were trained to work on electric vehicles. This statistic is worrying – with the number of EVs on the road increasing every year, it is vital that technicians have the necessary skills and qualifications required to work on them.

Whilst the overall braking system may be very similar, there are some unique differences between an EV and ICE vehicle which require specialised knowledge and expertise for maintenance and repairs. Technicians must understand the interaction between electronic controls and mechanical components.

They must also be aware that EVs are high voltage and practice proper safety procedures. This is why training is so important when it comes to servicing electric vehicles – not only for the safety of the driver, but also for the safety of the technician working on the vehicle.

Workshops must continually invest in upskilling their workforce in order to keep up in a competitive industry.

TMD Friction supports workshops with the transition to electric vehicles with a variety of educational measures, including webinars, dedicated in-person trainings, and the Textar Virtual Academy, an interactive learning hub which offers a dedicated unit on EVs and regenerative braking: https://tva.textar.com/

Conclusion
Maintaining the braking system in any vehicle is crucial for ensuring safety, performance, and longevity. When it comes to electric vehicles, understanding the unique characteristics of regenerative braking technology, conducting regular inspections, monitoring brake disc corrosion, checking brake fluid boiling points, and educating drivers on proper tyre maintenance will ensure EV owners keep their brakes in optimal condition.

As we head towards to a more electric mobility future, garages need to adapt, embrace the new technology and upskill technicians – or face being left behind.

TMD Friction and Textar will be exhibiting at the 2026 Auto Trade EXPO, which takes place alongside the CV Workshop EXPO from 10th -11th October at the RDS Simmonscourt in Dublin.