Replacing Brake Pads on Ultegra ST‑R8160 TT: A DIY Guide

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The Shimano Ultegra ST‑R8160 TT is a high-performance time trial and triathlon-specific dual-control lever, designed for optimal aerodynamics and precise braking under extreme conditions. Replacing brake pads on this model is a routine yet essential maintenance task that ensures peak performance and rider safety. This guide outlines the complete process for replacing the brake pads on the ST‑R8160 TT, focusing on Shimano’s direct mount caliper brakes typically paired with this system.

Tools Required

  • 5mm Allen key
  • Flathead screwdriver or pad spacer
  • Needle-nose pliers (optional)
  • Clean rag or isopropyl alcohol
  • Replacement Shimano-compatible brake pads (e.g., R55C4 or equivalent)

Understanding the Brake System Compatibility

The Ultegra ST‑R8160 TT shifters are most commonly integrated with Shimano’s direct-mount rim brake calipers. These calipers use cartridge-style brake pads mounted on holders. The design enables precise control during time trial braking situations while maintaining easy access for maintenance. Compatibility is essential; always choose Shimano-specific cartridge brake pads or high-quality third-party equivalents.

When to Replace Brake Pads

Inspect the brake pads regularly. Replace them if:

  • The wear indicators are no longer visible.
  • Grooves in the pads have smoothed out.
  • You hear a gritty noise when braking, indicating possible debris or metal-on-rim contact.
  • Braking performance diminishes, especially in wet conditions.

Regular inspection, especially after wet rides, helps prevent damage to your rims and ensures consistent stopping power.

Preparing for Replacement

Start by shifting to the smallest rear cog to provide chain slack and brake arm clearance. This setup helps with accessing the brake calipers. Position the bike in a stable work stand to allow easy wheel and caliper access. Clean the surrounding area with isopropyl alcohol to remove brake dust and oil residue before proceeding.

Removing the Old Brake Pads

Each brake pad is secured in a cartridge-style holder, retained by a small bolt or pin:

  • Loosen the retention bolt using a 2mm or 3mm Allen key (depending on the holder model).
  • Slide the pad backward out of the holder. If the pad is stuck, gently work it loose using a flathead screwdriver, taking care not to damage the holder.
  • Repeat the process for both front and rear calipers.

Note the orientation of each pad. Shimano pads are directional, with an arrow indicating the wheel rotation direction.

Installing New Brake Pads

Before installation, check that the new pads are the correct type (typically R55C4 for aluminum rims):

  • Slide the new pad into the holder in the correct orientation.
  • Ensure the pad fully seats into the holder without gaps.
  • Reinsert and tighten the retention bolt to the specified torque (typically 1–2 Nm). Do not overtighten, as this can strip the threads or warp the holder.
  • Repeat the process on all calipers.

Ensure that the pad is aligned with the rim surface and does not touch the tire or hang below the braking surface.

Adjusting Pad Alignment

Proper pad alignment ensures optimal braking force and prevents rim damage:

  • Position the pad so it sits flat against the braking surface.
  • Use a toe-in technique where the front of the pad touches the rim slightly before the rear. This reduces squealing and improves modulation.
  • Fine-tune the alignment by loosening the pad holder bolt slightly and manually adjusting the pad position.
  • Retighten to secure once aligned.

Check both the horizontal (rim height) and vertical (rim width) alignment.

Brake Caliper Centering

After pad replacement, verify that the brake calipers are centered over the wheel:

  • Squeeze the brake lever and check that both pads engage the rim simultaneously.
  • If not, use a 5mm Allen key to turn the centering screw located on the caliper.
  • Adjust until both sides engage evenly.

Centering ensures symmetrical braking power and consistent feel at the lever.

Testing Brake Performance

With new pads installed and calipers centered:

  • Squeeze the brake levers firmly to test engagement.
  • Spin the wheels and check for pad rub.
  • Perform a brief road test, applying gentle braking to bed in the pads.

Expect a short break-in period during which pad performance gradually improves as they conform to the rim surface.

Maintenance Tips for Longevity

To maximize the life of your new brake pads and maintain optimal performance:

  • Wipe rims and pads after wet or muddy rides to remove grit [paid link].
  • Inspect for embedded debris that can damage rims.
  • Re-torque pad bolts periodically to maintain a secure fit.
  • Store your bike indoors to avoid weather-related pad degradation.

Routine cleaning and inspections enhance both pad life and braking efficiency.

Common Issues and Troubleshooting

Brake squeal: Often caused by poor alignment or contamination. Re-align the pads with toe-in or clean them thoroughly.

Uneven pad wear: May result from misaligned pads or caliper arms not moving evenly. Check caliper centering and pad orientation.

Pad dragging on the rim: Usually due to improper centering or sticky pivots. Adjust the centering screw or inspect for mechanical resistance.

Poor braking power: Can indicate glazed pads, contamination, or worn rims. Clean or replace pads and check rim surface condition.

Customization and Performance Optimization

While the ST‑R8160 TT system is designed for speed and control, pad selection can further refine performance:

  • For wet conditions or training, consider pads with a softer compound for better grip.
  • For racing, use harder compounds that last longer and provide more consistent modulation under heat.

Experimenting with toe-in angles and compound types can offer subtle improvements in braking behavior, tailored to rider preferences.

Model Comparison: Ultegra ST‑R8160 TT vs Dura-Ace ST‑R9180 TT

The Ultegra ST‑R8160 TT offers excellent value with high-end features at a mid-tier price. Compared to the Dura-Ace ST‑R9180 TT:

  • The Ultegra model uses slightly heavier materials but retains top-tier ergonomics.
  • Both support similar pad and caliper compatibility, making pad replacement processes nearly identical.
  • Dura-Ace features more premium finishes and slightly refined lever feel, appealing to elite racers.

For most time trialists, the ST‑R8160 TT delivers outstanding performance with minimal trade-offs in weight and aesthetics.

Frequently Asked Questions

Q1: How often should I replace the brake pads on the Ultegra ST‑R8160 TT?
A: Replace them when wear indicators disappear or braking performance noticeably declines, typically every 2,000–4,000 km depending on conditions.

Q2: Can I use third-party brake pads with the ST‑R8160 TT system?
A: Yes, but they must be compatible with Shimano cartridge holders and match your rim type (aluminum or carbon).

Q3: What’s the recommended torque for pad retention bolts?
A: Shimano recommends 1–2 Nm. Always use a torque wrench for accuracy.

Q4: How can I stop my brakes from squealing after pad replacement?
A: Apply toe-in alignment to the pads and clean both pad and rim surfaces thoroughly.

Q5: Are the ST‑R8160 TT brake pads the same as other Ultegra models?
A: Yes, they generally use the same pad types as other Ultegra rim brake systems.

Q6: Is it necessary to remove the wheel to replace the brake pads?
A: No, but removing the wheel may provide easier access, especially for fine-tuning alignment.

By following this guide, you’ll ensure your Ultegra ST‑R8160 TT brake system remains responsive, safe, and race-ready. Regular maintenance not only improves performance but also extends the life of your entire braking system.