1. © 2012 Delmar, Cengage Learning Brake Service Chapter 58

2. © 2012 Delmar, Cengage Learning Objectives Inspect brake systems and recommend needed repairs Diagnose brake system problems Perform brake repairs and adjustments using the correct materials and procedures

3. © 2012 Delmar, Cengage Learning Introduction and Brake Inspection This chapter deals with hydraulic brake systems –Inspection –Diagnosis –Repair Thorough inspection of the braking system –Performed before any repairs Start with pedal and master cylinder

4. © 2012 Delmar, Cengage Learning Check Brake Pedal Feel Check the travel of brake pedal –Apply foot brakes Should be ample amount of pedal reserve Pedal should feel firm, not spongy –Spongy brake pedal indicates air or moisture in the system Calling for a brake bleed

5. © 2012 Delmar, Cengage Learning Master Cylinder Inspection Fluid movement past vent port –Should always be visible when pedal is applied Heavy surge from compensating port –Indicates air in system Power booster: operating correctly –Sound of air rushing into booster Apply the brakes –Test brake lights Hydraulic safety switch service –Brake warning lamp operates during braking

6. © 2012 Delmar, Cengage Learning Brake Diagnosis and Undercar Checks Brakes that pull to one side –Causes: suspension or steering systems Brake pedal pulsation –Results when hydraulic pistons move during stop –Brakes grab cause: oil or grease on lining –Brake pull: several reasons Undercar checks –Perform a visual inspection of brakes with vehicle raised on a hoist

7. © 2012 Delmar, Cengage Learning Disc Brake Inspection Disc brakes are inspected to see that a sufficient amount of friction material remains on pads –Remove a front wheel and visually inspect pad –Inspect the rotor –Check rotor runout with a dial indicator –Inspect rotor thickness and brake drums –Inspect the caliper and wheel seals –Test parking brake –Inspect tubing and hoses –Check for fluid leaks

8. © 2012 Delmar, Cengage Learning Inspecting Drum Brake Assemblies Important steps –Remove and mark the brake drum Spray the flange area with penetrating oil Use a hammer to rap on drum –Inspect drum brake cylinders –Inspect drum brake linings –Check self-adjuster operation

9. © 2012 Delmar, Cengage Learning Brake Fluid Service and Brake Fluid Testing Correct fluid to use is listed on reservoir –Space must be left to allow fluid expansion Fluid change interval –Change fluid every two years or 30,000 miles Brake fluid testing methods –Moisture content testers –Refractometer testing –Voltmeter testing –Fluid test strips

10. © 2012 Delmar, Cengage Learning Bleeding Brakes and Brake Bleeding Methods Air or moisture in system can result in soft pedal –Brakes are bled through a bleed screw Manufacturers specify bleeding sequences Brake bleeding methods –Manual bleeding and manual bleeding with a hose –Pressure bleeding and vacuum bleeding –Reverse fluid injection and gravity bleeding Several problems can occur during bleeding Scan tool to may be required to cycle the ABS Avoid contamination with petroleum products

11. © 2012 Delmar, Cengage Learning Adjusting Brakes Improper brake adjustments –Cause a low, firm pedal Diagnosis –Pump pedal twice quickly to correctly diagnose Pedal height rises higher on second application: brakes need adjustment –Most brakes today have self-adjusting mechanisms

12. © 2012 Delmar, Cengage Learning Master Cylinder Service and Master Cylinder Removal Cover vent is obstructed –Air can be drawn in at back of master cylinder, aerating fluid Air in fluid causes a spongy pedal –Check the vent when checking fluid level Removing master cylinder –Be sure to use fender covers –Use a vacuum brake bleeder to empty fluid from master cylinder reservoir Then remove master cylinder

13. © 2012 Delmar, Cengage Learning Master Cylinder Disassembly Master cylinders can be purchased as new or rebuilt –Bore of a cylinder is corroded or pitted: cylinder must be replaced Quick take-up master cylinders are serviced in the same manner

14. © 2012 Delmar, Cengage Learning Bench Bleeding the Master Cylinder Before installing a master cylinder –Fill with fluid and bleed air Quick take-up cylinder –Casting is larger near the rear Pedal free travel –Checked when master cylinder replaced Should be less than 1/8” of free play

15. © 2012 Delmar, Cengage Learning Brake Job Front or rear linings are replaced in pairs –Consult the appropriate service manual Complete brake job includes: –All internal hydraulic parts of wheel cylinders and disc calipers –New brake fluid, hardware, and springs –Drums and rotors may be remachined on lathe Ethics in brake work –Include disclaimer when incomplete brake job is advertised

16. © 2012 Delmar, Cengage Learning Drum Brake Lining Removal Clean entire assembly before disassembling brakes –Brake dust is dangerous to breathe Low-pressure wet brake washers are the most popular way of cleaning brake assemblies HEPA vacuum can also be used Removal of brake linings –Requires special tools

17. © 2012 Delmar, Cengage Learning Rebuilding Hydraulic Cylinders Hydraulic wheel cylinders and disc brakes can be rebuilt if made of cast iron and not corroded –Two kinds of hone are available After honing: install new rubber parts

18. © 2012 Delmar, Cengage Learning Reassembling a Wheel Cylinder and Removing Wheel Cylinders Reassembling a wheel cylinder –Lips on the wheel cylinder cups face toward fluid –Use brake fluid liberally as an assembly lubricant Removing wheel cylinders –Pitted or corroded: must be replaced –Use flare-nut wrench to remove brake tubing fitting –Cylinder is held to backing by two screws or clip Requires special service tool

19. © 2012 Delmar, Cengage Learning Replacing Drum Brake Shoes Important steps –Clean backing plates Use high-temperature lubricant on pads –Inspect brake springs Shoe return springs should not be loose or broken –Service self-adjusters Must be installed on the correct side of the car

20. © 2012 Delmar, Cengage Learning Adjusting Drum Brake Clearance Initial clearance adjustment –Made before drums installed Brake adjusting gauge –Adjusted to size of drum Star wheel of adjuster –Turned until shoes expand to size of adjusting gauge Manual adjustment –Can be done while the drum is installed

21. © 2012 Delmar, Cengage Learning Drum and Rotor Service Drum or disc lining are replaced –Common practice: remachine drums or rotors Too much metal must be removed: replace

22. © 2012 Delmar, Cengage Learning Drum Service Maximum amount that can be cut from most drums is 0.060” –Typical larger drum lists a discard diameter that is 0.090” larger than original Important points –Inspect drums to see that they are not out-of- round or scored –Be sure there is no oil or grease on drum –Drums and rotors can be mounted on a lathe –Tool bit at end of the cutter is a carbide insert

23. © 2012 Delmar, Cengage Learning Rotor Service Rotor in good condition –Provides better surface than freshly machined Rotors are always machined in pairs Machining a rotor –Cut both sides at once, maintaining equal force on both sides –Newly machined surfaces must be cleaned

24. © 2012 Delmar, Cengage Learning On-Vehicle Rotor Machining On-the-car brake lathes: becoming more popular –Before reinstalling a brake rotor: clean any rust preventive material from surface –Use a torque wrench when tightening lug nuts

25. © 2012 Delmar, Cengage Learning Disc Brake Service Important points –Disc linings are usually easy to replace –Most caliper designs require removal of caliper to remove pads –Before you install replacement pads in a floating caliper, check the condition of its slides –Open the bleed screw before retracting the piston –All pistons must be compressed at the same time

26. © 2012 Delmar, Cengage Learning Rear Disc Pad Installation and Rebuilt Calipers Rear disc pad installation –Rear-wheel disc brakes have a built-in parking brake –If there is a lever, do not force the piston into the bore Rebuilt calipers –Many shops find it more cost-effective to install rebuilt calipers Unloaded and loaded

27. © 2012 Delmar, Cengage Learning Disc Caliper Rebuilding Major steps –Disassemble caliper –Clean and inspect caliper parts –Inspect the pistons –Reassembly caliper –Install disc pads in the caliper

28. © 2012 Delmar, Cengage Learning Selecting Brake Linings Various lining materials are available –Depends on application and friction characteristics desired Older brake lining materials –Classified as organic or inorganic Side edge of a new brake lining –Stamped with code number established by SAE Aftermarket friction material certifications –Assure aftermarket lining performance characteristics equal to or better than new cars

29. © 2012 Delmar, Cengage Learning Disc Brake Noise Brake noise and vibration –Most likely complaints from a customer –Important that disc linings be firmly attached –Most pads have anti-rattle clips –Metal-to-metal contact points must be lubricated to prevent noise –Install caliper on correct side –Today’s linings are more fully cured but still require some break-in

30. © 2012 Delmar, Cengage Learning Parking Brake Cable Service During a rear brake job –Disconnect emergency brake cables from brake linings –Wipe off cables and apply clean grease Brake cable requires replacement –Use small hose clamp to remove it from backing plate Brake should be fully applied at half travel –Follow manufacturer’s recommendations

31. © 2012 Delmar, Cengage Learning Vacuum Power Brake Service Repairs to power boosters include replacement of the hose, filter, or check valve Causes of increased pedal effort –Installation of larger diameter tires –Defective power booster Vacuum booster operation test –Exhaust all vacuum reserve from power booster Power brake booster problems –Can be due to a hole in the booster diaphragm or a stuck valve that is leaking

32. © 2012 Delmar, Cengage Learning Vacuum Power Brake Service (cont’d.) Defective power booster –Causes brakes to drag Vacuum supply checks –Check hose that supplies vacuum to the power booster from intake manifold Power brake booster problems –Hole in booster diaphragm or a stuck valve Typical power boosters –Have four studs that protrude through the bulkhead into the passenger compartment

33. © 2012 Delmar, Cengage Learning Brake Warning Lamp Diagnosis Hydraulic safety switches –Found on vehicles that do not have fluid level sensing systems Fluid level switches –Found on vehicles that do not have hydraulic safety switch Check operation of stoplight switch –Apply brakes and verify that stoplights come on –Use a wiring diagram to determine how the circuit operates

34. © 2012 Delmar, Cengage Learning Antilock Brake System (ABS) System Service Covered in Chapter 59