Brake System PDF

C H A P T E R
© Cengage Learning 2014
1 4
Disc Brake System Principles
Chapter Objectives
At the conclusion of this chapter you should be able to:
t *EFOUJGZUZQFTPGEJTDCSBLFT
t *EFOUJGZEJTDCSBLFDPNQPOFOUT
t %FTDSJCFEJTDCSBLFPQFSBUJPO
KEY TERMS
brake pads dust boot shims
brake rotors fade square seal
caliper pistons fixed calipers squealer
composite rotor floating calipers
Copyright 201 Cengage Learning. All Rights Reserved. May not be copied, scanned, or duplicated, in whole or in part. Due to electronic rights, some third party content may be suppressed from the eBook and/or eChapter(s).
Editorial review has deemed that any suppressed content does not materially affect the overall learning experience. Cengage Learning reserves the right to remove additional content at any time if subsequent rights restrictions require it.
346 Chapter 14 • Disc Brake System Principles
Disc Brake Systems Brake pads

and Components
Even though disc brakes are not a new design, they were
not widely adopted for use in passenger vehicles until the Hydraulic
1960s. Drum brakes were used on the front and rear of pressure
many vehicles, and disc brakes did not become standard
equipment on many domestic vehicles until the 1970s.
Since then, disc brakes have become standard on the
front and rear of most passenger cars and light trucks
sold today.

Disc Brake Systems
Front disc brakes are standard on all modern cars and Disc or
light trucks, and disc brakes are often utilized for the rotor
rear brakes as well. The main advantages of disc brakes FIGURE 14-1 Basic operation of the disc brake system;
compared to drum brakes are: hydraulic pressure pushes the pistons against the pads, which
rub against the rotor to slow its rotation speed.
• Increased resistance to brake fade
• Quicker shedding of water from the friction surfaces
• Self-cleaning of dust and debris
• Self-adjusting
A disadvantage of disc brakes is that they require sig-
nificant force to clamp the pads against the brake rotor.
This increases the effort by the driver to slow and stop
the vehicle. Because of this, disc brake-equipped cars
require the use of a power assist system to decrease
driver effort and fatigue.
Disc Brake Types and Operation

All disc brakes are similar in operation: pressurized

brake fluid forces the caliper piston outward from the
caliper bore, which applies pressure against the brake
pads. This squeezes the two brake pads against the rotor
or disc, as illustrated in Figure 14-1. The pads pressing
against the rotor create friction and heat. The friction
FIGURE 14-2 An example of a common type of front disc
slows the disc, which in turn slows the wheel and tire.
brake assembly.
The heat is dissipated into the air.
Disc Brake Calipers are widely used on most passenger cars and light trucks
The caliper is the hydraulic output for the disc brake in service today.
system. Each caliper contains one or more pistons.
The number of pistons depends on caliper design and Fixed Calipers. Fixed calipers, like the caliper
its application on the vehicle. The caliper houses the shown in Figure 14-3, have at least two pistons. Hydrau-
piston(s) and pads and attaches to the steering knuckle, lic pressure forces each piston out with equal force so
partially covering the rotor. An example is shown in that both brake pads apply equally against the rotor.
Figure 14-2. Fixed calipers are bolted directly to the steering knuckle.
There are two major types of disc brake calipers, the The brake pads are often held in place within the cali-
fixed and floating caliper designs. Fixed calipers tend per by a set of pins or covers, as shown in Figure 14-4.
to be larger and are mostly used on high-performance By removing the pins, the pads can be replaced without
applications. Floating calipers are smaller, lighter, and removing the entire caliper assembly.
Chapter 14t Disc Brake System Principles 347

FIGURE 14-3 An example of a fixed brake caliper. This design

has pistons on both sides of the rotor.
Since hydraulic pressure is transmitted without loss,

the pressure applied to the inner and outer caliper pis
tons is the same. This means that each piston will be FIGURE 14-4 Fixed calipers use pins or bolt-on covers to
applied with equal force against the brake pad and retain the pads.
rotor, as shown in Figure 14-5. A brake hose supplies
Caliper
Boot
Seal
Hydraulic Hydraulic
pressure pressure
Piston
Rotor
FIGURE 14-5 This illustration shows the operation of a fixed caliper. Hydraulic pressure
is equal in the caliper, so each piston moves with the same amount of force against
each pad.
Fluid passage

FIGURE 14-6 Inside of a fixed caliper. Internal passages
allow fluid to pass from one side to the other.
brake fluid to the caliper, and internal passages in the

caliper supply fluid to the outer pistons, as shown
in Figure 14-6. The piston seal, sometimes called a
square seal, seals each piston in the bore. A dust boot
protects the outside of the piston and the piston bore
from debris. The dust boot is an accordion-type seal,
FIGURE 14-7 An example of mounting bolts on a floating
meaning it will expand and contract to cover the piston
caliper.
as the piston moves outward in the bore. Fixed calipers
have at least one bleeder screw, and some designs have
more than one to provide complete bleeding of air from
the system. Floating calipers generally use only one or two pis-
When the brakes are applied, hydraulic pressure tons mounted on the inboard side. A cross section of a
pushes on the back of each piston. As the piston moves floating caliper is shown in Figure 14-8. As hydraulic
outward in its bore, the piston seal deforms slightly, pressure forces the piston out of its bore, the caliper
twisting to follow the piston. When the brakes are body is forced in the opposite direction on the mount-
released, the caliper seal returns to its original shape, ing hardware. This is a result of Newton’s Third Law
pulling the piston back into the bore. By doing this, the of Motion: for every action there is an equal and oppo-
piston seal acts as a return spring for the disc brakes. site reaction, as shown in Figure 14-9 in the case of
As the brake pads wear, the pistons will move further caliper action. For the floating caliper to operate cor-
out of their bores to compensate for the space left by rectly and for both the inner and outer pads to wear
the worn pads. When the brakes are applied, the high equally, the caliper must be able to move freely on the
pressure in the hydraulic system forces the pistons out mounting hardware. As the brakes are exposed to nor-
and takes up the void in the caliper piston bore. When mal operating conditions, rust and corrosion can limit
the brakes are released, the piston seal returning to its the caliper’s ability to float. This will lead to uneven
normal shape cannot force the piston back more than a pad wear.
very slight amount. So each time the brakes are applied A variation of the floating caliper is the sliding
and the pads wear slightly, the piston also moves a very caliper. Sliding calipers do not use mounting bolts or
slight amount further out of the bore. This is how the disc pins; instead they are mounted so that they can slide
brakes self-adjust for wear. on the steering knuckle. An example is presented in
Figure 14-10. An example of a common sliding cali-
Floating Calipers. The most widely used type of per used for many years on Ford vehicles is shown in
caliper is the floating caliper. This is because float- Figure 14-11. The operation of the sliding caliper is the
ing calipers are less susceptible to pulsation from rotor same as that of the floating caliper, in that it must be able
runout and because they are smaller and lighter than to move in response to piston movement.
fixed calipers. Floating calipers are mounted so that Both floating and sliding calipers operate hydrauli-
they can move laterally on bolts or pins, as shown in cally, the same as fixed calipers. When the piston is forced
Figure 14-7. outward by hydraulic pressure, the piston seal deforms
Chapter 14 • Disc Brake System Principles 349
Bleeder screw Pads
Brake line
connection
Pad
spring Caliper
body
Hollow piston
Piston

seal
Rotor
FIGURE 14-8 This illustration shows the inside view of a floating caliper.
Caliper support
Reaction (anchor plate)
Caliper
Caliper
ways
Action Caliper
housing
Piston
Hydraulic
pressure
FIGURE 14-9 Floating calipers use Newton’s Third Law—for

every action there is a reaction. If the caliper is floating prop-
erly, the hydraulic force on the piston also pushes the caliper
backward to apply force against the outboard pad.
Retaining
screw
slightly, as shown in Figure 14-12. When the brakes are Caliper

released, the piston seal retracts the piston. Floating and support
Caliper
sliding calipers self-adjust in the same fashion as do fixed spring Antirattle
support
calipers. A dust boot protects the outside of the piston and spring
the bore just as in fixed caliper designs. FIGURE 14-10 An illustration of a type of sliding caliper.

FIGURE 14-11 An example of a sliding caliper used on a FIGURE 14-13 Examples of steel and phenolic plastic caliper
Ford vehicle. pistons.
modern vehicles have aluminum calipers to reduce

weight.
Caliper pistons are made of steel, phenolic plastic,
or aluminum. Examples of steel and phenolic pistons
are shown in Figure 14-13. Steel pistons have been in
service for many years and continue to be widely used.
Before application
Steel pistons are strong and can be fitted very close in
the caliper bore, usually within 0.005 inches. Phenolic
plastic pistons have also been in use for many years and
are used to reduce weight. Plastic pistons, while lighter,
Seal deflection have much thicker walls than comparable steel pistons
to increase strength. Plastic pistons tend to expand more
than steel pistons and require a larger clearance to the
piston bore, typically 0.008 to 0.010 inches. Many cali-
During application pers use aluminum pistons. Aluminum pistons are light-
weight and strong, having the advantages of both steel
and plastic pistons.
As discussed above, the caliper piston seal is a
square seal, housed in a recess in the piston bore, as
shown in Figure 14-14. The inner surface of the seal
encircles the piston, prevents fluid loss, and acts as a
piston return spring. The dust boot is attached to the
outside edge of the piston bore, and its inner surface

attaches to the outer lip of the piston. This is shown in
After application Figure 14-15 with the seal removed from the caliper
for clarity. As the piston moves outward, the dust boot
expands to protect the outside surface of the piston.
FIGURE 14-12 During operation, the square seal deforms Dust boots may be secured to the caliper with a snap
slightly. When pressure drops, the seal returns to its original ring, by a press-fit between the seal and the caliper, or
shape, which pulls the piston back into its bore.
with the lip of seal placed into a groove cut into the
caliper body.
Caliper Construction. Calipers can be made Floating calipers have mounting bolts, pins, or bush-
from cast iron or aluminum. Many older vehicles use ing bores, as shown in Figure 14-16. Many calipers
cast iron calipers since they are strong, have adequate bolt directly to the steering knuckle, as shown in
heat dissipation abilities, and are inexpensive. Most Figure 14-17, while other vehicles use a caliper support
Piston seal

FIGURE 14-14 The square seal keeps fluid in the caliper and

acts as the return spring for the piston.
Dust boot
FIGURE 14-17 Some vehicles have the caliper mount directly

to the steering knuckle, as in this example.
bracket to hold the pads and caliper to the knuckle, as

shown in Figure 14-18.
Calipers that are bolted to the knuckle often use a
combination mounting bolt and sleeve that rides in the

caliper body, as shown in Figure 14-19. The bolt/sleeve
Caliper
allows the caliper to move backward as the piston is
piston pushed against the inner pad.
Vehicles that use a mounting bracket often use a type
FIGURE 14-15 The piston dust boot protects the surface of of floating pin that connects the caliper to the bracket,
the piston as it extends further out of the bore as the pads and like that shown in Figure 14-20. The caliper bolts to the
rotor wear.
Caliper
housing
Bushing Mounting
bolt
Lube exterior of
bushing and bolt
Flexible with brake lubricant
seal boot
FIGURE 14-16 The bolts and sleeves allow the caliper to float in operation, meaning the
caliper can move side-to-side as the piston moves out and back into the bore.
352 Chapter 14t Disc Brake System Principles
Caliper bracket Caliper
These bolts hold

This bushing the bracket to the
and bolt secure steering knuckle.
the caliper to
the bracket.

FIGURE 14-18 Many cars and trucks use a support bracket FIGURE 14-20 An example of a caliper and support bracket.
that mounts to the knuckle, and the caliper then bolts to the
bracket.
FIGURE 14-21 Springs, clips, and retainers of various shapes

and sizes are used to hold the pad and prevent vibration and
noise.
Most caliper arrangements use some type of hardware

to reduce pad noise. Pad clips, like the type shown in
Figure 14-21, are used to keep the pads secure in the
FIGURE 14-19 An example of a caliper that bolts to the bracket and to reduce vibration and noise. The pads
knuckle without a bracket. must be able to move laterally in the clips, but they are
held tight radially to prevent noise. Many pads also use
pins, which float in the bracket. When the brakes are shims attached to the pad backing, like those shown in
applied, the caliper piston moves against the inner pad, Figure 14-22, to help reduce noise. Many replacement
and the caliper moves backward as the pins extend out pads have the shims attached to the backing plate, while
of their bores in the bracket. other pad sets have shims with adhesive backs that need

Airflow
FIGURE 14-22 Shims are used to alter the frequency of pad

vibrations so that they are inaudible to humans.
to be applied to the pads when they are installed. Regard-

less of the type of shims and hardware, it is important
that these pieces be installed and that they are installed
correctly.
Dirt and water
Disc Brake Rotors. The brake rotors are half of FIGURE 14-24 An illustration of how airflow through the
the friction components in disc brake systems; the pads rotor draws heat away from the brakes.
are the other half. Rotors, also called brake discs, are
mounted to the hub and rotate with the wheel and tire. As
the caliper clamps the brake pads against the rotor, a sub-
stantial amount of friction is created between the pads heat is generated all around the rotor’s surfaces. As the
and rotor. This friction is what slows the wheel and also rotor spins, air is pulled through the vents to remove
causes the intense heat generated by the brakes. Because heat from the friction surfaces and cool the rotor, as
of the stresses of braking and the heat that is generated, shown in Figure 14-24. The front brake rotors on all
brake rotors have to be strong and able to withstand high modern cars and trucks are vented. Nonvented or solid
operating temperatures. rotors, like the rotor in Figure 14-25, are used on the
The most common brake rotors are made of cast iron rear of some vehicles, and they can be found on the front
and have two friction surfaces separated by vents. The of some older, smaller vehicles. Nonvented rotors can
center of the rotor, called the hat, provides the mount- be used in the rear since the rear brakes are doing less
ing point for the rotor on the hub. The center hub hole is work than the front brakes, and the additional cooling
designed to fit precisely to the hub. Replacement rotors is not necessary.
should always be checked against the original rotors to For many vehicles, the vents in the rotors are simply
ensure that the hat areas match and that the rotors will straight passages from the outside to the inside of the
correctly fit the vehicle. The type of rotor pictured in hub or hat section of the rotor. Some vehicles use rotors
Figure 14-23, is called a vented rotor. The vents are that have curved or directional vents. Rotors with direc-
located between the two friction surfaces. The overall tional vents have improved airflow for better heat dissi-
friction surface area is large, but the contact area of the pation, but they must be installed on the correct side of
pads is small. As the pads are pressed against the rotor, the vehicle to work correctly.
Swept area
two surfaces
100 Square Inches
FIGURE 14-23 An illustration of a brake rotor and the amount of surface area of the friction surfaces.
Ventilated rotor
Braking surfaces

Solid rotor
FIGURE 14-25 Examples of vented and solid rotors.
Cast iron
friction Steel
surfaces web

FIGURE 14-26 Composite rotors use a steel hat to reduce
weight.
FIGURE 14-27 An example of a high-performance rotor,
cross-drilled to vent gases and dust.
Some rotors, instead of being made completely of
cast iron, are a composite of a steel hub and iron fric-
tion surface, like the composite rotor in Figure 14-26. surface, as shown in Figure 14-28. When the brakes are
This type of rotor offers a slight weight reduction over applied, the point of application between the pads and
a cast iron rotor. rotors can create a gas barrier that reduces braking abil-
Brake rotors on some high-performance vehicles may ity. The holes and slots in these rotors allow this gas to
be drilled and/or slotted. Drilled and/or slotted rotors are escape, which improves braking.
common on motorcycles but are not generally found on Some high-performance vehicles offer ceramic-
passenger cars or trucks. Drilled rotors, like that shown composite brake rotors. These rotors and pads offer
in Figure 14-27, have a series of holes drilled through extreme heat dissipation, reduced weight, and the abil-
the friction surface. Slotted rotors are similar except that ity to withstand high-speed braking with reduced fade
the slots do not go through the entire depth of the friction or distortion. Fade is the term used to describe the loss

FIGURE 14-30 Examples of brake pads. Pads come in many
sizes and shapes depending on how they are mounted.

pad friction material determine its coefficient of friction
and ultimately, how well the vehicle stops. As with brake
shoe linings, brake pad friction materials vary depend-
ing on the manufacturer and the application. Common
ingredients include iron, steel, copper, synthetic fibers,
FIGURE 14-28 An example of a high-performance rotor that and ceramics.
is slotted. The slot improves pad cleaning and also helps reduce
Brake pads, as shown in Figure 14-30, are shaped
gas and dust.
to follow the curve of the brake rotor. When the caliper
piston(s) move outward, the pads are pressed against the
rotor with great force, which result in friction and gen-
of braking power or performance, usually as a result of erate heat. The pads must be made from materials that
heat. Ceramic-composite brakes are optional equipment can not only withstand the friction and heat of braking,
on cars such as the Corvette Z06 and on many other vehi- but also be able to operate effectively when the brakes
cles, but they can add several thousand dollars to the are cold. Brake pad linings are a compromise between
price of the car. several factors, such as pad life, noise generation, and
cold and hot coefficients of friction. Brake pads that use
Disc Brake Pads. Brake pads, which are comprised soft friction compounds offer quiet operation and will
of the friction material or pad lining and the backing or not wear the brake rotors very fast, but will themselves
support plate for the lining, clamp down on the brake wear quickly and may not have the stopping power of
rotor to slow the wheel. The parts of a brake pad are semi-metallic or metallic pads that contain metal shav-
shown in Figure 14-29. The materials that make up the ings and other materials that increase stopping perfor-
mance. Semi-metallic pads, however, will cause more
rapid wear of the rotor and also tend to generate more
Backing
noise and rust-colored brake dust.
Tab Antirattle
plate Pads are often categorized as asbestos, organic, semi-
spring
metallic, or ceramic. Asbestos pads were made with
asbestos fibers, which tolerated the high temperatures
generated by the brake system but also produced dust
that if inhaled, could cause lung damage and cancer.
Tab Asbestos has been phased out of brake linings since the
1990s. Organic pads are made of natural compounds
such as glass and Kevlar. These pads are softer and cre-
Lining
ate less noise but also wear faster and make a lot of
brake dust due to the softer compounds. Semi-metallic
Wear pads contain iron, steel, copper, and graphite, which
indicator are mixed together into the friction compound. Semi-
FIGURE 14-29 The parts of a brake pad. Not all pads have metallic pads offer longer service life but also wear the
antirattle clips mounted on them; many use shims and spring- brake rotors faster and can generate more brake noise
loaded clips between the pad and caliper bracket to reduce and dust. Many newer brake pads use ceramic fibers and
noise. other materials, such as copper, and are often considered

FIGURE 14-31 An example of pads with grooves for dust
dispersion and chamfered edges to reduce noise. The groove
also provides an indication of wear. When the pad is worn to FIGURE 14-33 A close up of a wear indicator.
the point where the groove disappears, the pad needs to be
replaced.
the rotor during braking. Chamfering the leading edges
of the pads helps decrease noise.
superior to other pads due to their ability to dissipate Many pads have a built-in wear indicating device,
heat, long service life, provide quiet operation, and gen- sometimes called a squealer due to the noise it makes
erate low dust. when it comes into contact with the rotor, as shown in
Brake pads often have grooves and chamfers cut into Figure 14-32. Figure 14-33 shows an example of a wear
the lining, as shown in Figure 14-31. Grooves are used indicator tab. Some pads use an electrical pad wear indi-
to help remove the dust generated between the pad and cator that is embedded into the pad’s friction material.
Pad Pad
Rotor Rotor
Wear Wear
indicator indicator
New pad Worn pad
FIGURE 14-32 The wear indicator makes a high-pitched noise when it contacts the
spinning rotor.
Chapter 14t Disc Brake System Principles 357
The pad shown in Figure 14-34 has the electrical con REAR DISC BRAKE SYSTEMS
nector and sensor used to alert the driver when the pads Rear disc brakes are replacing rear drum brakes on
are worn out. An example of how this looks installed on more and more cars and trucks. Rear disc brakes oper
the vehicle is shown in Figure 14-35. This sensor acti ate exactly like those on the front, but they are smaller in
vates a warning light on the dash, an example of which is both rotor and pad size.
shown in Figure 14-36, to alert the driver that the brake
pads need to be inspected and/or replaced. Rear Disc Brake Designs. Rear disc brakes can
be either fixed caliper or floating caliper designs. Fixed
DBMJQFSTUFOEUPCFVTFEPOIJHIFSQFSGPSNBODFWFIJDMFT
compared to floating calipers. Rear brake rotors can be
either vented or solid, depending on the requirements of
the vehicle. Figure 14-37 and Figure 14-38 show a front
and rear disc brake assembly for comparison. The front
rotor is vented, and the pads are larger than those used on

the rear brake. The rear rotor is also a solid rotor.
Rear Disc Brakes and Parking Brakes. All

vehicles sold in the United States are required to have
a parking or emergency brake. The parking brake is a
FIGURE 14-34 An example of a pad with an electronic wear
indicator.

FIGURE 14-35 This brake system uses electronic pad wear
sensors. The wire leading into the center of the caliper is FIGURE 14-37 An example of a front rotor for comparison
attached to the brake pad sensor. to a rear rotor, shown in Figure 14-38.
FIGURE 14-36 When the pad wears to the point when FIGURE 14-38 An example of a rear rotor for comparison.
the sensor touches the rotor, the warning light on the dash is Rear rotors have smaller pads and typically, a narrower friction
illuminated. surface area.
Piston
seal
Cone
Piston
Screw
Parking brake
Rotor lever

Outboard Inboard
brake pad brake pad
Internal thread
nut
FIGURE 14-39 An illustration of an integral parking brake caliper. The piston is threaded to the parking
brake lever to provide a mechanical connection, not dependent upon the hydraulic system.
mechanical brake that often uses components of the The ball-and-ramp design uses an actuator with reliefs
hydraulic service brakes but does not rely on the hydrau- that are cut into its surface. The reliefs are tear drop
lic system to operate. This is so that in the event of a loss shaped and are deeper at the large end and shallow at
of hydraulic pressure, the parking brake can be used to the point. Ball bearings are placed between the piston
slow and stop the vehicle, albeit with a much longer stop- and the actuator and sit in the reliefs. When the parking
ping distance. brake is applied, the actuator turns and the ball bearings
When the parking brake is part of the rear disc brake move from the deep to the shallow part of the relief. This
caliper, it is called an integral parking brake caliper. action pushes the bearings against the piston to set the
Figure 14-39 shows an illustration of this type of caliper. brake. When it is released, the actuator rotates back and
The piston, under normal braking, is applied by hydrau- the bearings recess back into the reliefs.
lic pressure, but when the parking brake is applied, a
lever pushes the caliper piston out slightly, which locks
the pads against the rotor. There are two methods for
applying the caliper piston with the parking brake, a
threaded piston and a ball-and-ramp design.
A threaded caliper, as shown in Figure 14-39, uses a
threaded piston and a screw that passes through the cali-
per body. When the parking brake is set, the brake cable
pulls on the lever at the back of the caliper. An example is
shown in Figure 14-40. The lever is attached to the rear
of the screw, and the front of the screw is seated against
the rear of the caliper piston. When the lever rotates the
screw, the screw turns in the caliper and pushes against

the piston. The piston moves out slightly, setting the pads
against the rotor. A spring, often located at the rear of the
caliper at the lever, retracts the lever and screw when the
parking brake is released. FIGURE 14-40 An example of an integral rear brake caliper.

FIGURE 14-41 An example of a drum in hat rear brake
system.

Drum in Hat Designs. Another type of rear park-
ing brake system is called the drum in hat design, shown
in Figure 14-41. In this arrangement, the rear disc brakes
operate exactly as the front disc brakes. The only differ-
ence is that the inside of the hat of the rear rotors con- FIGURE 14-42 A rear brake caliper containing an electrically
tains a machined surface. This surface is the brake drum operated parking brake motor.
for a set of small brake shoes, which are used only as the
parking brake. Servicing this type of brake is covered in
detail in Chapter 13. Prius, Honda Insight and Civic hybrids, and others are
single-piston floating caliper designs. What is differ-
Electrically Operated Parking Brake. A new ent about how the brakes operate on hybrid vehicles is
development in rear disc brakes is the use of an elec- that the on-board computer system monitors brake pedal
trically operated parking brake system. Two types of input and then controls braking through the regenera-
systems are in use: one system uses an electric motor tive process and the service brakes. This means that even
to pull the parking brake cables, and the other uses a though the driver is pressing the brake pedal, the com-
motor housed in each of the rear calipers. An example of puter system is determining how much braking will be
a caliper with a motor is shown in Figure 14-42. In both done by the hydraulic brake system. The split between
designs, the motors are not designed to be used to stop hydraulic braking and regenerative braking depends on
the vehicle in the event the service brakes fail; instead, many factors but is mostly dependent upon the HV bat-
the system is used only for holding the vehicle in place tery state of charge. The idea is to recapture as much
when it is parked. energy as possible to recharge the HV battery. However,
Servicing these systems will require the use of a scan when the battery is charged, the system will greatly
tool. Refer to the vehicle’s service information for spe- reduce or stop the amount of energy recaptured by the
cific service procedures. brakes. In the event of a malfunction in the braking cir-
cuits, the regenerative system is disabled, and normal
Hybrid Vehicle Disc Brakes. As discussed in brake operation remains.
Chapter 10, hybrid vehicles can recover braking energy One special brake service note for Ford Escape
to recharge the high-voltage (HV) batteries. Because of Hybrid vehicles: these vehicles perform periodic brake
this, the service brakes tend to last much longer on these system integrity tests when the vehicle is parked and
vehicles than on nonhybrids. On vehicles such as the Toyota off. During this test, the brake system is pressurized
Prius, the driver can select the B mode while driving, for short periods of time. To perform brake services
which allows even more brake energy to be recaptured. on these vehicles, it is necessary to place the vehicle
The B mode is designed to utilize more regenerative brak- into Pad Service Mode. This will prevent the self-test
ing than the mode for normal driving conditions. from operating. To perform brake service and place the
The disc brakes on hybrids operate exactly like those vehicle into service mode, refer to the manufacturer’s
on nonhybrid vehicles. The disc brakes on the Toyota service procedures.
SUMMARY
Disc brakes are less prone to fade than drum brakes. Pad clips and shims are used to keep the pads secure in
There are two major types of disc brake calipers, the the bracket and reduce vibration and noise.
fixed and floating caliper designs. Some pads use an electrical pad wear indicator that is
Fixed calipers are bolted directly to the steering embedded into the pad’s friction material.
knuckle. When the parking brake is part of the rear disc brake cali-
Floating calipers move laterally on bolts or pins. per, it is called an integral parking brake caliper design.
REVIEW QUESTIONS
1. A caliper that is mounted directly to the steering 8. Which of the following is not a common type of
knuckle and has a piston on each side of the rotor disc brake rotor?
is called a caliper. a. Composite steel hat and iron friction surface
2. The seal in the caliper seals the b. Drilled or slotted friction surface
brake fluid around the piston and allows for self- c. Composite aluminum friction surface and steel hat
adjustment.
d. Solid friction surface and cast iron hat
3. A rotor with a cast iron friction surface and a thin
9. All of the following statements about disc brakes
stamped steel hat is called a rotor.
are true except:
4. Clips and are commonly used to a. Disc brakes resist fade better than drum brakes
limit the noise generated by disc brakes.
b. Disc brakes are self-adjusting
5. The seal around the caliper piston c. Disc brakes require less application force than
prevents fluid loss and acts as the piston return drum brakes
spring.
d. Disc brakes are commonly used on the rear
6. Calipers can be which of the following types? wheels
a. Floating c. Fixed 10. Technician A says that pad wear indicators may
b. Sliding d. All of the above turn on a warning light on the dash. Technician B
says pad wear indicators may make a loud
7. Technician A says all fixed-caliper designs have at
squealing noise when the pad is worn too thin.
least two pistons. Technician B says some floating
Who is correct?
calipers use two pistons. Who is correct?
a. Technician A c. Both A and B
a. Technician A c. Both A and B
b. Technician B d. Neither A nor B
b. Technician B d. Neither A nor B

Brake System PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Brake System PDF

Uploaded by

Copyright:

Available Formats

C H A P T E R

© Cengage Learning 2014

Disc Brake Systems Brake pads

© Cengage Learning 2014

Disc Brake Types and Operation

© Cengage Learning 2014

© Cengage Learning 2014

© Cengage Learning 2014

Since hydraulic pressure is transmitted without loss,

© Cengage Learning 2014

brake fluid to the caliper, and internal passages in the

© Cengage Learning 2014

Bleeder screw Pads

© Cengage Learning 2014

FIGURE 14-9 Floating calipers use Newton’s Third Law—for

slightly, as shown in Figure 14-12. When the brakes are Caliper

© Cengage Learning 2014

© Cengage Learning 2014

modern vehicles have aluminum calipers to reduce

outside edge of the piston bore, and its inner surface

© Cengage Learning 2014

© Cengage Learning 2014

FIGURE 14-17 Some vehicles have the caliper mount directly

bracket to hold the pads and caliper to the knuckle, as

combination mounting bolt and sleeve that rides in the

Caliper bracket Caliper

These bolts hold

© Cengage Learning 2014

© Cengage Learning 2014

© Cengage Learning 2014

FIGURE 14-21 Springs, clips, and retainers of various shapes

Most caliper arrangements use some type of hardware

© Cengage Learning 2014

FIGURE 14-22 Shims are used to alter the frequency of pad

to be applied to the pads when they are installed. Regard-

© Cengage Learning 2014

100 Square Inches

© Cengage Learning 2014

FIGURE 14-25 Examples of vented and solid rotors.

© Cengage Learning 2014

© Cengage Learning 2014

© Cengage Learning 2014

© Cengage Learning 2014

© Cengage Learning 2014

New pad Worn pad

© Cengage Learning 2014

Rear Disc Brakes and Parking Brakes. All

© Cengage Learning 2014

© Cengage Learning 2014

© Cengage Learning 2014

screw, the screw turns in the caliper and pushes against

© Cengage Learning 2014

© Cengage Learning 2014

You might also like