OK, so I'm a fairly new MINI owner (though I did once own an original Morris Mini Minor with the magic-wand shifter, back in the day!), and I've got the dreaded 'amber brake pad warning' light on my 2008 Type 52 Cabriolet. I've had a look here on the forum and discovered it's due to a worn-down front sensor.

Right. Wheels up and off, and I took a close look at the sensor. It was worn down to where the spring-contacts were gone, but I still had plenty of pad material left, so I figure it was somewhat premature in its warning. All the same, since I had a set of Green-Stuff pads in stock, I decided to do a full-on front brake maintenance anyway.

Being basically a cheap, impatient b*st*rd, I had a look to see what could be done about that sensor without having to wait around for a mail-ordered replacement and all the fiddling to R&R it. I also didn't want to lose the functionality of the sensor, since it does provide a useful purpose. The solution seemed pretty simple, and in the end, it was.

I removed the old sensor from the pad and unhooked the rubber bit under the brake bleeder to give me some line to work with. I then carefully filed down the face of the sensor, but only enough to expose the two pins that use to attach to the now-gone spring thingy that would touch the rotor. This left me with two shiny bits of metal which were flush with their hard-plastic holder. I then used some acid-based flux and acid solder (I tried non-acid but it didn't want to take) and managed to tin the two pin ends. I then laid a nice strip of solder between the two pins and soldered that on. This left me with a strip of solder connecting the two pins. Went in, switched on the ignition to position #2, waited the requisite 30 seconds and -ping- the lamp went out, as expected. I then went ahead and changed out the pads, lubed the slider-pins, etc. to complete the full brake job.

Now, when the pads wear down, the sensor will contact the disk and the soft solder will eventually wear down and separate, doing no damage to the disk, and re-lighting the warning lamp, as desired. At that point, I can once again (now that the pins are nicely tinned) repair it with another strip of solder, making the sensor reusable many times over.

I know you're thinking - "what if the brake pads get so hot as to melt the solder?" Well, I thought about that, but after having driven for over 300 miles now and having done some pretty vigorous braking, it has yet to let go, so I don't think that's an issue. YMMV, of course.

Cheap, impatient b*st*rd, scores 1. Pricey MINI bits & aggro, 0.

 

Nicely done!

 

Thanks. Helps to be basically cheap.