Modern Automotive Technology

erP o i n t f o r
Pow Modern Automotive

Technology
by
Russell Krick
Publisher
The Goodheart-Willcox Co., Inc.
Tinley Park, Illinois
© Goodheart-Willcox Co., Inc. Permission granted to reproduce for educational use only
Chapter 71
Brake System
Fundamentals
Contents
 Basic brake system
 Braking ratio
 Brake system hydraulics
 Brake system components
 Parking brakes
Automotive Brakes
 Provide a means of using friction to
either slow, stop, or hold the wheels of
a vehicle
 When a car is moving, it has kinetic
energy (inertia)
 To stop the vehicle, the brakes convert
mechanical (moving) energy into heat
Basic Brake System
Brake Operation
 When the driver pushes on the brake
pedal, lever action pushes a rod into
the brake booster and master cylinder
 The pressure developed in the master
cylinder forces fluid through the brake
lines to the wheel brake assemblies
 The brake assemblies use this
pressure to cause friction for braking
Parking Brake
 The parking brake system uses cables
or rods to mechanically apply the rear
brakes
 Provides a system for holding the
wheels when the vehicle is parked, or
stopping the vehicle during complete
hydraulic brake system failure
Drum and Disc Brakes
 Two common types of brake
assemblies:
 Disc brakes
often used on the front wheels
 Drum brakes
often used on the rear wheels
Drum and Disc Brakes
Disc brakes Drum brakes
Braking Ratio
 Comparison of front wheel braking
effort to rear wheel braking effort
 When a vehicle stops, its weight tends
to transfer onto the front wheels
 The rear tires lose some of their grip
 The front wheels must do more of the
braking
Typical Braking Ratios
 Rear-wheel drive vehicles:
front brakes may handle 60% to 70% of
the braking, rear brakes handle 30% to
40%
 Front-wheel drive vehicles:
more weight is concentrated on the front
wheels
braking ratio is even higher at the front
wheels
Brake System
Hydraulics
 Automotive brakes use a hydraulic
system
 Hydraulic brakes use confined brake
fluid to transfer brake pedal motion and
pressure to each of the wheel brake
assemblies
Hydraulic Principles
 Liquids in a confined area will not
compress
 When pressure is applied to a closed
system, pressure is exerted equally in
all directions
 Hydraulics can be used to increase or
decrease force or motion
Hydraulic System Action
 Pressure and motion can be
transferred from one cylinder to
another
 Cylinders of the same size:
if one piston is moved, the other will move
the same amount with the same force
 Cylinders of different size:
if the smaller piston is moved, the larger
piston will move with more force but will
move a shorter distance
In a hydraulic jack, a
small piston acts on a
large piston, resulting
in great force, but a
small amount of
movement
Hydraulic jack operation

Hydraulic Brake Action
 The master cylinder acts as the
pumping piston that supplies system
pressure
 The wheel cylinder acts as the power
piston, moving the friction linings into
contact with the rotating drums or
discs
Hydraulic Brake Action
Brake System
Components
Brake Pedal Assembly
A lever to increase the force applied to

the master cylinder piston
Master Cylinder
 Foot-operated pump that forces fluid to
the brake lines and wheel cylinders
 Develops pressure to apply the brakes
 Equalizes pressure required for braking
 Keeps the system full of fluid as the
linings wear
 May maintain a slight pressure to keep
contaminants from entering the system
Master Cylinder
Brakes applied Brakes released
Master Cylinder
Components
Master Cylinder
Components
 Cup and piston
used to pressurize the system
when they are pushed forward, they trap
fluid, building pressure
 Intake port
allows fluid to enter the rear of the
cylinder as the piston slides forward
fluid flows from the reservoir, into the area
behind the piston and cup
Master Cylinder
Components
 Compensating port
releases pressure when the piston returns
to the released position
fluid can flow back into the reservoir
through the compensating port
 Residual pressure valves
maintain residual fluid pressure of
approximately 10 psi (69 kPa) to help
keep contaminants out of the system
Master Cylinder
Components
 Rubber boot
prevents dust, dirt, and moisture from
entering the back of the master cylinder
 Reservoir
stores an extra supply of brake fluid
cast as part of the housing or added as a
removable plastic part
Piston and Cup
Residual
Pressure
Valve
Brakes applied, fluid
flows freely
Brakes released, the

valve closes to
restrict the return of
fluid to the master
cylinder
Dual Master Cylinder
 Uses two separate hydraulic pistons
and two fluid reservoirs
 Each piston operates a hydraulic circuit
that controls two wheel brake
assemblies
 If there is a leak in one of the hydraulic
circuits, the other circuit can still
provide braking action on two wheels
Dual Master
Cylinder
(Normal Operation)
Both pistons produce pressure to all four

wheel brake assemblies
(Rear Brake Circuit Leak)
Primary piston pushes on the

secondary piston, two wheel brake
assemblies still work
(Front Brake Circuit Leak)
Secondary piston slides forward,

primary piston operates two
wheel brakes normally
Power Brakes
 Use a booster and vacuum or hydraulic
pressure to assist brake pedal
application
 The booster is located between the
brake pedal linkage and the master
cylinder
 When the driver presses on the brake
pedal, the brake booster helps push on
the master cylinder pistons
Vacuum Booster
 Uses vacuum produced in the engine
intake manifold or by a separate pump
to apply the hydraulic brake system
 Consists of a housing that encloses a
diaphragm
 When vacuum is applied to one side of
the booster, the diaphragm moves
toward the low-pressure area
Vacuum
Booster
Operation
Atmospheric Suspended
Brake Booster
 Atmospheric pressure is present on
both sides of the diaphragm when the
brakes are released
 When the brakes are applied, vacuum
is routed to one side of the booster
 Atmospheric pressure then pushes on
and moves the diaphragm
Vacuum Suspended
Brake Booster
 Vacuum is present on both sides of the
diaphragm when the brakes are
released
 When the brakes are applied, vacuum
is released from one side of the
booster
 Atmospheric pressure then pushes on
and moves the diaphragm
Vacuum Brake Booster
Hydraulic Booster
 Uses power steering pump pressure to
help the driver apply the brake pedal
 Known as hydro-boost or hydra-booster
 Commonly used on vehicles with
diesel engines
diesel engines do not produce a usable
amount of intake manifold vacuum
Hydraulic Booster
Hydraulic Booster
When the pedal pushes on the unit, the

spool valve allows more oil to enter the
pressure chamber, pushing on the
power piston
Brake Fluid
 Specially blended hydraulic fluid that
transfers pressure to the wheel brake
assemblies
 Rated by the SAE and DOT
SAE (Society of Automotive Engineers)
DOT (Department of Transportation)
Brake Fluid
 Brake fluid must have the following
characteristics:
correct viscosity at all temperatures
high boiling point
noncorrosive
water tolerant
lubricates components
low freezing point
Brake Lines and Hoses
 Transfer fluid pressure from the master
cylinder to the wheel brake assemblies
 Lines
made of double wall steel tubing
tubing ends usually have double-lap flares
 Hoses
made of reinforced rubber
used where flexing action is necessary
Brake Lines and Hoses
Brake Line Hardware
Brackets and
clips secure the
hoses and lines
to prevent
damage
Brake
Systems
Often used on rear-
wheel-drive vehicles
Often used on front-

wheel-drive vehicles,
with high front-to-rear
brake ratio
Disc Brake Assembly
The assembly consists of a caliper, brake

pads, a rotor, and hardware
Single Piston Caliper
The caliper slides as the piston moves in

to clamp the brake pads against the rotor
Fixed Caliper
The caliper remains stationary as pistons

on each side clamp the rotor
Brake Caliper Assembly
Caliper Components
 Piston seal
prevents fluid leakage between the piston
and the cylinder
helps pull the piston back into the cylinder
when the brakes are not applied
 Boot
prevents road dirt and water entry
 Bleeder screw
allows air to be removed from the system
Caliper Operation
 When the brakes are applied, brake
fluid flows into the caliper cylinder
 Fluid pressure pushes the piston
outward, forcing the brake pads into
the rotor
 When the brakes are released, the
stretched piston seal pulls the piston
back into the bore, as fluid pressure
drops
Caliper Operation
Brakes applied Brakes released

Disc Brake Pads
 Steel plates to which linings are riveted
 Linings
made of heat-resistant organic or
semimetallic friction material
semimetallic linings withstand higher
temperatures without losing their
frictional properties
Disc Brake Pads
 Anti-rattle clips
keep the brake pads from vibrating and
rattling
 Pad wear sensor
metal tab on the brake pad
emits a loud squeal when it scrapes
against the brake disc when the lining has
worn too thin
Brake Disc (Rotor)
 Uses friction from the brake pads to
slow or stop wheel rotation
 Normally made of cast iron
 Constructed as part of the hub, or a
separate unit
 May be solid, or a ventilated rib
construction
Disc Brake Assembly
This rotor is vented to increase cooling

Floating Caliper
 The disc brake is mounted on two bolts
supported by rubber bushings
 Uses one piston
 The caliper is free to shift, or float, in
the rubber bushings
Sliding Caliper
 Uses one piston
 Mounted in slots machined in the
caliper adapter
 The caliper is free to slide sideways in
the slots as the linings wear
Fixed Caliper
 Uses more than one piston and caliper
cylinder
 The caliper is bolted directly to the
steering knuckle
 Pistons on both sides of the disc push
against the brake pads
Drum Brake Assembly
A large drum surrounds the brake shoes

and the hydraulic wheel cylinder
Backing Plate
 Holds the springs, wheel cylinder, and
other parts inside the drum
 Helps keep road dirt and water off the
brakes
 Bolts to the axle housing or the spindle
support
Wheel Cylinder
Assembly
Uses master cylinder pressure to force

the brake shoes out against the drum
Wheel Cylinder
Components
 Boots
keep road dirt and water out of the
cylinder
 Pistons
metal or plastic plungers that transfer
force out of the cylinder to the brake
shoes
 Cups
rubber seals that keep fluid from leaking
past the pistons
Wheel Cylinder
Components
 Springs
hold the rubber cups against the pistons
when the wheel cylinder assembly is not
pressurized
metal expanders may be used on the ends
 Bleeder screw
provides a means of removing air from
the brake system
Brake Shoes
 Rub against the revolving brake drum
to produce braking action
 Made by fastening organic friction
material onto a metal shoe
rivets or bonding agents may be used
 The front shoe is the primary shoe
uses the shortest lining
 The rear shoe is the secondary shoe
uses the largest lining surface area
Brake Shoes
 Retracting springs
pull the brake shoes away from the brake
drums when the brake pedal is released
 Hold-down springs
hold the brake shoes against the backing
plate when the brakes are in the released
position
Drum Brake Assembly
Brake Shoe Adjusters
 Maintain the correct drum-to-lining
clearance as the brake linings wear
 Automatic adjusters normally function
when the brakes are applied with the
vehicle moving in reverse
 If there is too much lining clearance,
the brake shoes move outward and
rotate with the drum enough to operate
the adjuster lever
Cable-type star wheel adjuster

Link-type star wheel adjuster

Lever-type star wheel adjuster

Cable-type star wheel adjuster with an

overtravel spring
Lever-latch adjuster
Sliding-latch adjuster
Brake Drums
Provide a rubbing surface for

the brake shoe linings
Brake Shoe Energization
 When the brake shoes are forced
against the rotating drum, they are
pulled away from their pivot point by
friction
 This self-energizing action draws the
shoes tighter against the drum
 Servo action results when the primary
shoe helps apply the secondary shoe
Brake Shoe
Energization
Self-Energizing Action
Primary shoe is self-
energized
Servo Action
Less hydraulic pressure is
needed to apply the
brakes
Control Valves and
Switches
Stoplight Switch
 Operates the rear brake lights
 Normally open switch, usually mounted
on the brake pedal mechanism
 When the brake pedal is pressed, it
closes the switch
Brake Warning Light
Switch
 Also called the pressure differential
valve
 Warns the driver of a pressure loss on
one side of a dual brake system
 If a leak develops in either the primary
or secondary brake system, unequal
pressure pushes the switch piston to
one side, grounding the indicator
circuit
Brake Warning Light
Circuit
Brake Warning Light
Switch
Pressure difference pushes the piston to

close the warning lamp circuit
Low-Fluid Warning Light
Switch
 Turns on a dash light if the brake fluid
in the master cylinder becomes low
 Often mounts in the master cylinder lid
or cover
 Commonly operated by a float
Metering Valve
 Used to equalize braking action on
vehicles with front-wheel disc brakes
and rear-wheel drum brakes
 Located in the line to the disc brakes
 Prevents the front brakes from applying
until pressure reaches approximately
75–135 psi (517–930 kPa)
 This pressure overcomes the rear
brake return springs
Proportioning Valve
 Used to equalize braking action on
vehicles with front-wheel disc brakes
and rear-wheel drum brakes
 Located in the line to the drum brakes
 Limits pressure at the rear drum brakes
when high pressure is needed to apply
the front disc brakes
 Minimizes rear-wheel lockup during
heavy braking
Combination Valve
 Single unit that functions as a brake

warning light switch, a metering valve,
and/or a proportioning valve
 Common on late-model vehicles
Combination Valve
Master Cylinder
Incorporates a proportioning valve and a

warning light switch
Parking Brakes
Parking Brake Operation
 When the hand or foot lever is
activated, it pulls a steel cable that runs
through a housing
 The cable pulls on a lever inside the
drum or disc brake assembly, forcing
the brake linings against the rear
drums or discs
Parking Brake
Components
Foot-operated
parking brake
pedal
A lever pushes the

shoes against the
drum
Parking Brake Operation
(Rear Disc Brakes)
 A thrust screw and a lever can be

added to the brake caliper
 When the parking brake is applied, the
cable pulls on the caliper lever
 The caliper lever turns the thrust screw,
which pushes on the caliper piston and
applies the brake pads to the disc
Rear Disc Brake Caliper
Note the parking brake mechanism


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erP o i n t f o r

Pow Modern Automotive

Disc brakes Drum brakes

Hydraulic jack operation

A lever to increase the force applied to

Brakes applied Brakes released

Brakes released, the

Both pistons produce pressure to all four

Primary piston pushes on the

Secondary piston slides forward,

When the pedal pushes on the unit, the

Often used on front-

The assembly consists of a caliper, brake

The caliper slides as the piston moves in

The caliper remains stationary as pistons

Brakes applied Brakes released

This rotor is vented to increase cooling

A large drum surrounds the brake shoes

Uses master cylinder pressure to force

Cable-type star wheel adjuster

Link-type star wheel adjuster

Lever-type star wheel adjuster

Cable-type star wheel adjuster with an

Provide a rubbing surface for

Pressure difference pushes the piston to

 Single unit that functions as a brake

Incorporates a proportioning valve and a

A lever pushes the

 A thrust screw and a lever can be

Note the parking brake mechanism

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