Development and production of asbestos-free brake pad using Palm Kernel Shell was studied with a view to replacing the use of asbestos whose dust is carcinogenic. The PKS were sieved into sieve grades of 100,350,710am and 1mm. The sieve PKS was used in production of brake pad in ratio of 20% resin, 10% graphite, 15% steel, 35-55% PKS and 0-20% SiC using compressive moulding. The properties examined are microstructure analysis, hardness, compressive strength, density, flame resistance water and oil absorption. The microstructure reveals uniform distribution of resin in PKS. The results obtained showed that the finer the sieve size the better the properties. The results obtained in this work were compared with that of commercial brake pad (asbestos based and optimum formulation laboratory brake pad palm kernel shell based (PKS)), the results are in close agreement. Hence PKS can be used in production of asbestos-free brake pad.