✅ 2025 Overview: Remanufacturing and Effects on BYD Discs/Pads
BYD 2025 models – including the Atto 3 , Seal U , Dolphin , and Seal models – use very effective regenerative braking . This is great for fuel economy, but reduced use of mechanical brakes can cause:
- Vitrification (glazing) of pads and/or discs due to lack of “thermal running-in”.
- Growing surface rust on discs (especially in humid climates).
- Hissing/squeal , vibrations and judder from irregular deposits.
🔧 Main BYD EV Brake Problems (2025 Update)
Collection of the most frequently reported critical issues from partner workshops on Atto 3, Seal U, Dolphin and Seal.
1) Vitrification of pads and/or discs
- Typical symptoms: prolonged/spongy braking, metallic noises, reduced effectiveness when cold.
- Causes: prevalent use of regeneration, insufficient thermal cycles, non-“reactivated” compound.
- Quick fixes: deglazing with fine sandpaper and thorough cleaning, performing controlled bedding cycles ; if worn/cracked: replace the discs and pads with the dedicated EV low-dust kit.
2) Rust on the discs and loss of bite (urban/wet use)
- Typical symptoms: creaking at first impact, noticeable orange patina, irregular braking.
- Causes: prolonged inactivity of mechanical brakes, humidity, road salt.
- Solutions: Clean discs/calipers with brake cleaner , brake 1–2 times hard at moderate speed to remove oxide; in severe cases, turn/replace discs.
3) Vibrations (judder) and whistling
- Symptoms: Vibration in pedal/steering wheel, high-pitched whine with light braking.
- Causes: pad imprinting (uneven deposits), poor caliper sliding, missing/worn anti-squeal plates.
- Solutions: Clean and lubricate caliper guides, check tightening torques, correct bedding-in ; if DTV (Disk Thickness Variation) is out of tolerance → replace discs.
4) Regeneration calibration vs. mechanical brake
- Symptoms: “on/off” brake, abrupt transition from regen to hydraulic in emergency.
- Causes: Regeneration settings too aggressive, “one-pedal” mode always active.
- Solutions: Soften regeneration in wet/icy city conditions, periodically alternate modes with lower regen to "keep the mechanical brakes alive"; software updates when available.
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🛒 Buy now on Amazon💶 Indicative costs for BYD EV brake repairs (workshop network range)
| Intervention | Symptom/Purpose | Range €* |
|---|---|---|
| Caliper/guide cleaning + brake cleaner | Whistles, poor flow | 60 – 140 |
| Deglazing tablets/discs + bedding | Vitrification, low mordant | 80 – 180 |
| Replacing EV low-dust pads | Chronic squeal/wear | 120 – 260 |
| Replacing discs + pads (axle) | DTV/judder, severe rust | 220 – 520 |
| DOT fluid purge + ABS diagnosis | Spongy pedal, periodic maintenance | 70 – 140 |
*Indicative ranges: vary by model, part quality (OEM/Aftermarket) and local labor.
🧭 Practical maintenance/use tips
- Every 1–2 weeks : perform 3–4 progressive braking operations up to 60→20 km/h to “clean” the discs.
- After rain/wash/long stop : apply 1–2 hard brake applications at low speed to dry the discs/pads.
- Regeneration mode : alternates regen levels; avoids fixed “one-pedal” in wet/snow conditions.
- EV coupons : check caliper/guide sliding, anti-noise plates, wheel tightening torques.
- Suitable compound : for intense city use, consider EV low-dust pads, which are more tolerant to cold cycles.
❓ Frequently Asked Questions
Why do the brakes on my BYD squeal often?
Poor use of the mechanical brake (regeneration) → patina/rust and deposits. Requires cleaning, bedding, and, if necessary, low-dust EV pads.
Does remanufacturing damage discs?
No: it makes them work less. But if the discs remain "cold" and oxidized, noise and judder can arise. Periodically alternate the use of the hydraulic brake.
How often should you replace the pads on an EV?
It depends on use: on EVs they often last longer, but time (oxidation/hardening) matters as much as mileage. Visually inspect every 12 months.
Is it better to deglaze or change everything?
If the thickness and DTV values are OK, deglazing and bedding are sufficient. If vibration and squeal persist, consider a disc and pad kit.
🏁 Conclusions
Regeneration is a plus on the BYD 2025 EV , but requires targeted maintenance of the mechanical brakes to prevent glazing, rust, and noise. With bedding cycles, periodic cleaning, and—when necessary—specific EV kits, efficiency and comfort are restored.
Having doubts about your BYD chassis? Contact us: we'll check disc/pad compatibility, regeneration settings, and updates for your model.
