1. UNIT REF: L107 UNIT TITLE: VEHICLE BRAKING SYSTEMS COMPONENTS AND
MAINTENANCE

2. Health and Safety When working with Braking system;
A. Ensure car is properly supported.
B. Ensure car is “Chocked”
Brake fluid is corrosive and must not get in your eyes or remain on the skin.

3. PPE to include :a. overalls b. protective and safety gloves
c. protective footwear
d. goggles
e. protective safety helmets
VPE protection to include:
a. wing covers
b. seat covers
c. carpet protection

4. Leverage and Hydraulics

5. hydraulics http://www.youtube.com/watch?v=TL3DcMZQEog&NR=1

6. Brake fluid

7. Friction

8. Basic braking system
Drum brakes

9. Modern braking system
Braking system diagramatic

10. The Brake Disc

11. Brake disc
Solid Disc
Drilled and vented

12. Brake Disks
Grooved discs give improved friction under extreme braking conditions
Drilled discs provide extra cooling to meet the demands of fast road conditions
Combi discs are the ultimate, benefiting from 12 grooves and cross drilling

13. Brake Calliper

15. Disc Brake calipers

18. Disc

20. Brake Pads

21. Brake Piston return tool

22. Brake Pads Greenstuff Brake pads High end brake pads with sensors
Frictional material
Backplate

23. Braking system components
Brake master cylinder & Brake Pedal.
Brake Calliper
Brake Pads
Brake Disc
Brake cylinder
Brake Shoes
Brake drum
Servo

24. Brake Master cylinder
brake master cylinder
Diagram

27. Video Braking system
Braking

28. Backing Plate

29. Brake Wheel Cylinder

30. Brake Drums

31. Brake Shoes

32. Brake drums and servo effect

33. Wheel Cylinder

34. Springs and retainers

35. Brake bleeding

36. Hand brake adjustment

37. Drum Brakes
Video

38. Leale's Transmission & Auto Repair
405 Keyes Street
San Jose, CA 95112
Office (408)
Fax    (408)  

39. Brake Servo

40. How disc brakes work
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41. Servo Function

42. Bleeding brakes

43. Fill Master cylinder

44. Carefully loosen bleed nipple

45. Brake nipples

46. Clear tube

47. Brake Adjuster (1)

48. Handbrake Brake adjuster (2)

49. Handbrake adjuster (3)

50. Troubleshooting Brake Problems -
Brake Pedal Too Low
If you step on the brake pedal and it feels like it's going too far down before you start to slow, you might have the following problems:
Low Brake Fluid Level: Check your brake fluid. If it's low, top it off to the mark on the side of the reservoir.
Contaminated Brake Fluid: Even though your brakes operate in a closed system, contaminants can still work there way into the works. Air can enter the system through the smallest hole, and you can end up with water in the system from condensation and other means. There's not really any way to check for this, but bleeding your brakes will remove the bad stuff and replace it with new fluid.

51. Faulty Brake Servo Unit
Worn Brake Pads: Your brakes should never wear low enough to cause your brake pedal to feel low, they'll scream at you before then. But if they do get very low, you might have this problem.
Replace your brake pads as soon as possible. Of course, this can be avoided with regular brake inspection.
Faulty Brake Servo Unit
Finally, if your brake Servo is faulty you'll have low brake pedal issues. Most brake servo’s are vacuum controlled, so a special vacuum measurement device that connects to the brake booster is needed to check it. If it's faulty, you'll have to replace the boost unit.

52. Brake Pedal Too Firm.
If you step on the brake pedal and all of a sudden it feels too firm. This symptom points to a few potential problems, all of which need to be fixed as soon as possible.
Vacuum Problems:
Your brakes are easier to press because of a brake Servo that gives your foot the strength of 10 men. This Servo uses vacuum to help you activate the brakes. If there is a vacuum leak somewhere in the system, it won't have enough negative pressure to do its job. Check the vacuum system for leaks. If you find none, your brake booster is probably bad and will need to be replaced
Brake Line Obstruction:
It's possible for something to block brake fluid from reaching a portion of the system. This could be something in the line like a chunk of rust, or it could be a pinched brake line. Visually inspect the brake lines and replace damaged brake lines as needed.

53. Brake Pedal Goes To Floor
Brake Pedal Goes To Floor. If you step on the brake pedal and it has little to no pressure and goes all the way to the floor, especially if you're getting no braking:
Low Brake Fluid Level:
Check your brake fluid. If it's low, top it off to the mark on the side of the reservoir.
Air in the Brake Fluid:
. Air can enter the system through the smallest hole. There's not really any way to check for this, but bleeding your brakes will remove the air and replace it with new fluid.
Master Cylinder Faulty:
A damaged master cylinder will cause your brakes to have no pressure. Master cylinders cannot be repaired and will need to be replaced.

54. Weak or Spongy Brakes.
Sometimes your brakes will still work, but they seem to have grown weak. It takes longer to stop, or you get less braking power when you apply the brakes suddenly. The pedal may also feel more squishy than usual:
Low Brake Fluid Level:
Check your brake fluid. If it's low, top it off to the mark on the side of the resevoir.
Contaminated Brake Fluid:
Even though your brakes operate in a closed system, contaminants can still work there way into the works. Air can enter the system through the smallest hole, and you can end up with water in the system from condensation and other means. There's not really any way to check for this, but bleeding your brakes will remove the bad stuff and replace it with new fluid.
Worn Brake Pads: Your brakes should never wear low enough to cause your brake pedal to feel low, they'll scream at you before then. But if they do get very low, you might have this problem. Replace your brake pads as soon as possible.

55. Brakes Grabbing or Pulling.
Your brakes should apply themselves smoothly and evenly when you push the pedal. If they seem to suddenly grab, or if they are pulling the car to one side, you may have one of these problems:
Worn or Bad Brake Pads:
If your brakes are very worn, or if they have become contaminated or are otherwise bad, you'll need to replace your brake pads.
Bad Brake Disc:
Inspect your brake discs. If one or both are bad, they can cause your brakes to grab suddenly or unevenly. You'll need to replace your brake discs. They should always be done in pairs, so don't try to skimp

56. Drum brakes have a ‘self-servo’ action, explain this term
Drum brakes have a ‘self-servo’ action, explain this term. Illustrate your answer with a diagram. (highlight the main components).
LV04 (2.2) (10 marks)
State two advantages of disc brakes compared to drum brakes
LV04 (2.3) (4 marks)
Draw a simple schematic diagram showing a dual-line braking circuit. State why this is used in preference to a single line system.
LV04 (2.2) (6 marks)
Explain the term ‘hygroscopic’ with respect to brake fluid. What effect will this have on brake fluid and what is done on a service to reduce this problem?

57. Correctly explains:
The rotating drum tends to drag and wedge the leading shoe into the drum,
this creates an additional self generated force.
4 marks
This diagram should show;
return spring
leading shoe
trailing shoe
wheel cylinder
shoe anchor
adjuster

58. Any 2 from:
Improved heat dissipation
Self-adjusting for lining wear
Pedal travel not affected by temperature
Brake force is proportional to pedal pedal/fluid pressure (no self servo)
2 marks each

59. A very simple diagram showing either an
L or X split brake circuit is sufficient 4 marks
Student should state increased safety failure of 1 circuit,
remaining circuit is still available 2 marks each

60. Brake fluid absorbs moisture from the air
(2 marks).
It affects the brake fluid by lowering it’s boiling point
(2 marks)
Regular brake fluid changes reducing this problem
(1 mark)