BRAKE SYSTEM SERVICING

Prepared by : Romeo V. Honrada Course : AMC-93C

Trainer : Publio Alcantara Jr. Date :

Procedure in replacement of master cylinder :

1. Park your vehicle and wear safety gear : Ensure your parking spot a good place. To protect yourself
from the brake fluid, which is corrosive, wear gloves and goggles.
2. Locate the various components of your vehicle’s brake system : pop the hood and find the brake system
for your vehicle. You can usually find the brake master cylinder directly under the brake fluid
reservoir. It will have brake fluid lines attached to it.
3. Siphon the brake fluid out of the reservoir : remove the treaded cap and insert a turkey baster into the
reservoir. Suck up the brake fluid and squeeze it out in a resalable container. Repeat the process to
remove as much fluid as possible.
4. Disconnect the brake fluid sensor : if your vehicle has an integrated brake booster remove the vacuum
hose connected to it to make it easier to access the sensor. Press the safety clip and gently tug the brake
fluid sensor away from the master cylinder.
5. Remove the brake lines and brake booster if your vehicle has one : place a rag underneath the brake
line connections to catch brake fluid. Use a flaring wrench to loosen and remove each of the brake
lines. Use a swivel extension to unfasten the master cylinder from the brake booster.
6. Detach the brake master cylinder : remove the all mounting bolts holding the master cylinder in place
with a wrench or socket. Take off washers as well then move the master forward off of the studs and
lift it out of the engine compartment.

Remove and Rebuild master cylinder

 Clamp a master cylinder to a workbench with a vice. Find a suitable workbench and secure the
master cylinder.
 Remove reservoir and hose. Remove the set bolt from the reservoir. Remove the reservoir with the
hose from the master cylinder.
 Remove the reservoir union. Remove union bolt. Remove the reservoir union and two gaskets.
 Remove the piston stopper bolt. Using a screw driver, push the piston in all the way and remove
the piston stopper bolt and gasket.
 Remove the piston and spring. Push the piston with a screw driver and remove the snap ring with
ring pliers. Remove the piston and spring from the master cylinder.
 Inspect a clean cylinder bore for rust and scoring wear or damage. If necessary clean or replace the
cylinder.
 Assemble the repair kit or new parts of master cylinder. Apply grease to rubber parts of piston.
 Install spring and piston. Be careful your work to not damage the rubber lips on the pistons. Insert
spring and piston straight in, not an angle. Using snap ring pliers, install the snap ring.
 Install piston stopper bolt and new gasket or sealant. Using a screw driver, push the piston in all
the way and install the piston stopper bolt through the new gasket or sealant.
 Install reservoir union. Install the union through the new gasket. Install and torque the union bolt.
 Install reservoir and hose. Connect hose the union and reservoir. Install the reservoir on the master
cylinder.
 Date Developed: Document No.
April 2020. Issued by:
BRAKES SYSTEM
SERVICING Developed by:
Revision # 01 0|Page
Romeo V. Honrada

Disc Brake Servicing and Procedures

Disassemble and Inspect

Remove the front wheels. Note: Before beginning this procedure, ensure that the vehicle is properly supported
on axle stands.

Inspect the hydraulic hoses attached to the brake calipers for bulges or cracks.

Determine if the bleed screws can be loosened. Use a six-point socket or wrench to avoid damaging the screw.

Remove the brake caliper. The procedure for removing the brake caliper varies from one vehicle to another. Use
the service manual to determine the correct procedure for the vehicle being worked on.
Note: Do not allow the caliper to hang by the hydraulic hose. Use a piece of mechanics wire to suspend the
caliper after its removal.

Remove the brake pads from the caliper. Press the caliper piston back into the bore using a block of wood or
equivalent and secure the piston with a c-clamp. The piston should move with moderate pressure on the clamp.

Inspect the caliper for signs of brake fluid leakage or damaged rubber boots.

Remove the brake rotors. On rear-wheel drive vehicles this usually requires the removal and disassembly of the
wheel bearings. On many front-wheel drive vehicles the rotor is held in place by the wheel and will come off
easily once the caliper is removed. Clean and inspect the wheel bearings.

Inspect the brake rotor for cracks, hot spots, or excessive wear. Measure the rotor with a micrometer to
determine if it is thick enough to be reused.

Based on your inspection, create a list of recommended service and required parts.
Your work must be inspected by the teacher before proceeding to the next procedure.

Repair or replace parts as discussed with instructor.

If the rotors require machining, mount the rotors in the brake rotor lathe. Set up the cutter. Have the teacher
inspect your machine set-up before starting the machine. Remove only enough material to true the rotors. Note:
Safety glasses are required for this procedure.

Repack the wheel bearings with grease. Thoroughly clean any filings from the rotors before installing the
bearings.

Clean and lubricate the pins or slides that allow the calipers to "float" on the rotors.
Install the rotors on the vehicle and adjust the wheel bearings. Lock the adjusting nut with the cotter pin and
install the dust cap.

Install the brake pads in the caliper, ensuring that any anti-rattle springs or anti-vibration compounds are in
place.

Install the brake calipers on the rotors. Use a thread-lock agent if required on the mounting bolts.

Fill the master cylinder brake fluid reservoir. Note: Avoid contacting skin with the brake fluid.

Check the brake lines for air. Have an assistant pump the brake pedal until the caliper piston moves out to firmly
hold the disc pads against the rotor. While holding firm pressure on the brake pedal, open the bleed screw and
check for air bubbles. Close the bleed screw before the assistant releases the brake pedal. Note: a commercially-
available brake bleeding system may also be used for this procedure.

Check the brake fluid level in the master cylinder.

Install and torque the wheel nuts and reinstall the hubcap.

Date Developed: Document No.

April 2020. Issued by:
DISC BRAKE
SERVICING AND
Developed by:
PROCEDURE Revision # 02 0|Page
Romeo V. Honrada

Drum brakes servicing

 Service Tools and Safety-As with disc brakes and other systems on modern vehicles, there are
special tools for drum brakes that make their service safer and easier for the technician. Using the
correct tool for the job and using the tool safely are important aspects of doing a job well. Incorrect tool
usage can damage the tool and the components being worked on and can cause personal injury. Brake
service tools are used to make the process of working with the brake system safer and easier. While
some technicians prefer to use basic hand tools when working on brake springs and other components,
it is best to use the tools specifically designed to perform certain tasks.
 BrAke ServiCe Pre-CAuTionS Performing drum brake service involves working with
many small parts and springs, sometimes connected in ways that are not readily apparent. Take time to
determine how the parts fit together before disassembling the shoes. Locate a diagram of the brake
assembly, or take pictures before you start to work; this will help you correctly reassemble the
components. In addition to wearing standard PPE such as safety glasses and work boots, gloves are
also recommended when you are working on drum brake assemblies. Mechanics gloves will help
protect your hands against cuts and keep the brake dust from working into your skin. Before you begin
working on the brakes
 Always allow the drum brakes to cool before beginning to service them.
 Familiarize yourself with the brake system before attempting service. If necessary, research system
operation before performing any type of work on the system.
 Locate and follow all of the manufacturer’s service procedures for working on the drum brake system.
 Do not reuse damaged parts.
 Do not reuse drums that are damaged or worn beyond their service limit.
  Use proper cleaning techniques to remove brake dust
 Familiarize yourself with how the brakes are assembled before taking them apart.
 Have a parts diagram or picture of the brakes as they are before disassembly.
 Take one side a part at a time; this allows you to keep the other side intact for reference.
 Use the appropriate brake tools for disassembly and reassembly.
 Carefully inspect all components as you take the brakes apart.

 If you finish to replace you try the vehicle if there is the problem
And then if it is okay
 You do a 5s

Date Developed: Document No.

April 2020. Issued by:
DRUM BRAKES
SERVICING Developed by:
Revision # 03 0|Page
Romeo V. Honrada

Brakes Bleeding
The Materials Needed For Bleeding Brakes

 A brake bleeder wrench

 A clean glass jar
 A can of brake fluid
 A helper

Procedures For Bleeding brakes :

Follow the bleeding brakes procedure step by step for how to bleed brakes your car the right way:

Step 1: Prepare Before Getting Into Action

Consult the owner’s manual to know which specific type of brake fluid your vehicle requires, also what
intervals the fluid inside need to be replaced. Brake fluid has many different types, and they don’t mix well. Get
to the auto parts store or dealer’s parts department to buy the correct fluid before you start working on the
bleeding job. Good-quality brake fluid is easily affordable; you may need two or three 12-ounce cans for how to
bleed the brake lines.

Step 2: Getting Your Car Ready For the Job

Using some jacks and stands, you can first jack up your vehicle on a level, solid ground. It should be a garage
floor or driveway surface. You then support the car with four jack stands placed at the jacking points shown in
the owner’s manual. It needs to be safely and firmly on solid footing while in the air. Remember the process of
bleeding brakes will have you got partially under the car at times so it should be safe for you. Finally you
remove all four wheels to begin.

Step 3: Locate the Brake Bleeder Screw

The first step is to jack up your car and crawl underneath. In order to do that, find the brake bleeder screw
located behind each of your brakes. Then driver can use the wrench to loosen but not remove the screw. If it’s
stuck, spraying some penetrant around it will make your job easier.

Step 4: Connect and Fill

Connect and fill the jar is actually an important step for drivers to know how to bleed brakes. Fit one end of a
hose into the end of the screw, and the put the other end in the glass jar or a bottle. Fill the jar with brake fluid at
a level so that the hose’s end is submerged. If you can’t find any flexible hose, keep the jar near the nozzle so
that it can catch the liquid squirting out of the nozzle.

Step 5: Test the Brake Fluid

You might need a friend to make this easier

Ask the helper (might be a friend or someone else) to sit in the driver’s seat and push the brake pedal several
times. After that, open the bleeder screw while asking the helper to hold the pedal down. Brake fluid will come
out of the nozzle, and you’ll see the bubbles (if there’s any) clearly. This is an essential step in  how to bleed
brakes.

Step 6: Remove The Bubble

Now, tighten the screw when the helper is still holding the pedal down. After, tell him/her to release the pedal
and repeat this process of loosening and tightening the screw until the fluid contains no more bubble. How to
bleed brakes is something him/her does not need to understand, they just need to help with the pedal. Tell the
helper to shout “Down” when pressing the pedal and “Up” when releasing it.

Step 7: Bleed The Brakes

In order to master how to bleed brakes, you have to bleed each of the brakes by repeating the same process.
However, it is necessary to fill up the master cylinder with brake fluid before bleeding each of the brakes. If you
don’t do it, the cylinder will be drained out of fluid and draw air into the lines. In that case, it is necessary to
bleed the master cylinder too.

Step 8: Master Cylinder Checking

After bleeding all four brakes, you ask your helper to apply full effort to the brake pedal followed by a sudden
all release. Look closely the motion of the fluid in the master-cylinder reservoir. If there is a substantial fluid
eruption, there would be air bubbles still trapped in the system. In that case you have to repeat the bleeding
procedure to remove that air.

Step 9: Tighten the Screw

After bleeding the last time and filling up the master cylinder to the full level, tighten the last bleeding screw.
Double-check until all the bleeder screws are tight. Again this time, apply solid pressure but not all of your
strength to tightening them – or else you may snap them off – before reinstalling the car’s wheels. Drive the car
a while to see if the brakes seem alright when you push the pedal.

 Brake bleeding is the procedure performed on hydraulic brake systems whereby the brake lines
(the pipes and hoses containing the brake fluid) are purged of any air bubbles. This is necessary
 because, while the brake fluid is an incompressible liquid, air bubbles are compressible gas and
their presence in the brake system greatly reduces the hydraulic pressure that can be developed
within the system. The same methods used for bleeding are also used for brake flushing or
purging, where the old fluid is replaced with new fluid, which is necessary maintenance.

There are five main methods of bleeding:

 The pump and hold method, the brake pedal is pressed while one bleed screw at a time is opened,
allowing air to escape. The bleed screw must be closed before releasing the pedal, or a one-way
valve must be fitted
 In the vacuum method, a vacuum pump is attached to the bleeder valve, which is opened and fluid
extracted with the pump until it runs clear of bubbles.
 In the pressure method, a pressure pump is attached to the master cylinder, pressurizing the
system, and the bleeder valves are opened one at a time until the fluid is clear of air. Specialised
pumps may incorporate a method to automatically keep the brake fluid reservoir full during
bleeding.
 In the reverse method, a pump is used to force fluid through the bleeder valve to the master
cylinder. This method uses the concept that air rises in liquid and naturally wants to escape up and
out of the brake system.
 Gravity bleeding is a simple and easy method replace automotive brake fluid. It can also be used to
bleed systems containing air bubbles but may not be as effective as other methods.

Date Developed: Document No.

April 2020. Issued by:

BRAKES BLEEDING
Developed by:
Revision # 04 0|Page
Romeo V. Honrada

BRAKE PEDAL AND HAND BRAKE

ADJUSTMENT

Warnings:

 Failure to support the vehicle's weight with jack stands, while working under it, can result in vehicle
damage and severe injury.
 Wear safety glasses and work gloves to prevent serious injuries.

Items you will need:

 Wheel chocks
 Floor jack
 Jack stands
 Lug wrench
 Brake adjusting spoon
  Socket set

Step 1

Secure the front wheels by placing wheel chocks in front of and behind both front tires. Lift the rear of the
Escape with a floor jack positioned under the center pivot of the rear suspension. Place jack stands under the
rear control arms for safety. Remove the rear wheels with a lug wrench and set them aside .

Step 2
Slide the rear drums off the brake shoes. If your Escape is equipped with rear disc brakes, remove the two 14
mm caliper bracket bolts that attach the caliper to the spindle with a 14 mm socket and ratchet. Lift the caliper
assembly off the rotor and slide the rotor off the parking brake shoes.

Step 3

Adjust the rear brake shoes on the drum brakes by prying out the adjustment cam on the equalizer located under
the wheel cylinder. Pry out on the cam with a small screwdriver until the drum just slides onto the shoes with
slight resistance. On disc brakes, adjust the parking brake shoes by turning the adjuster located between the
parking brake shoes. Rotate the adjuster with a pair of pliers until the rotor creates a slight drag on the shoes
when installed.

Step 4

Remount the wheels and test the parking brake. A properly functioning parking brake will fully apply the brake
when the lever is raised four to six clicks by the ratcheting mechanism. If the hand brake requires more travel
than this, adjust the lever free play.

Adjust the hand brake lever free play by gently prying the dust cover away from the lever until you can see the
adjusting nut located at the bottom of the lever. Turn the adjusting nut with a 10 mm socket on an extension and
ratchet until the parking brake can be fully applied.

Perform rear brake adjustment every 6 months

 First adjust the rear brakes by turning the wedge bolt, which is located on the bottom of the backing
plate.

1. Raise and safely support the vehicle on jack stands.

2. Remove the rubber cap from the adjusting screw.  
3. Tighten the adjuster until the wheel ceases to rotate.
4. Back off the adjuster 180°.
5. Verify that the wheel turns easily by hand.
6. Install the rubber cap on the adjuster screw.
7. Lower the vehicle.

Date Developed: Document No.

April 2020. Issued by:
BRAKES PEDAL AND
HAND BRAKE
ADJUSTMENT Developed by: Revision # 05 0|Page
 Romeo V. Honrada

Brakes troubles

Never Ignore These 8 Warning Signs of Brake Problems

1. Brake Light On. ...

2. Squealing, Squeaking or Grinding Noises. ...
3. Wobbling, Vibration or Scraping When Braking. ...
4. Leaking Fluid. ...
5. Spongy or Soft Brake Pedal. ...
6. Car Pulling to One Side When Braking. ...
7. Burning Smell While Driving. ...
8. Bouncing Up and Down When You Stop Short

Brakes not working well

Even today, your brakes can fail completely, but there are fail safes built into the system to prevent that from
happening in most cases. Every car since 1968 has had redundant hydraulic systems, not to mention the
parking/emergency brake, to prevent complete brake failure. The master cylinder actually contains two pistons
and seals, which in simpler systems controlled the front and back brakes separately, or the diagonally opposite
wheels, so at worse you would only lose half your brakes.

Soft Pedal - The brake pedal is easy to push but there is less braking.

 Low brake fluid

 Air in brake fluid
 Bad master cylinder
 Bad caliper/wheel cylinder
 Blown brake line
 Bad residual valve
 Fluid leak in system
 Boiled brake fluid
 Bad wheel bearing

Another uncommon cause of a soft pedal and long travel, is a bad wheel bearing, which is unrelated to
the brakes except for being in the vicinity of the rotors. The failing bearing allows the hub to move
around, effectively pushing the brake pads back into the caliper as far as it can.

Hard Pedal - It takes much more pressure to get the same amount of pedal travel and braking force.

 Bad power booster

 Vacuum hose leak
 Bad check valve
 Collapsed vacuum hose
 Seized caliper
 Extremely worn brake pads
 Most instances of a hard pedal come down to a failure in the power boost system, whether vacuum
based or hydro-boost (used mostly on diesels, we won't be covering it here). The power booster uses
engine vacuum to assist your leg when applying the brakes, and is nearly universal in modern cars. If it
the booster, check valve, or vacuum hose is bad, it will likely also cause a vacuum leak and rough
engine idle as well, but an engine with a bad valve or head gasket can also cause low vacuum which
can affect the brake boost.

Brakes hanging up/dragging

The other major way brakes act up is when they fail to disengage completely in one way or another. A common
symptom of this type of braking issue is a burning smell from the amount of heat the hung up brake generates.
Seldom does this result in a car that won't move at all, but driving with the brakes dragging is unsafe and will
result in even more damage in a short amount of time if not repaired.

Some of the cause of brakes dragging on one or more wheels can be:

 Seized caliper/pads
 Seized parking brake cable
 Rusted rotor/drum
 Clogged master cylinder return hole
 Pinched/collapsed brake line

Date Developed: Document No.

April 2020. Issued by:

BRAKES TROUBLES
Developed by:
Revision # 06 0|Page
Romeo V. Honrada

Driving Techniques
 When you drive defensively, you can be sure that you will always be in complete control when you are
behind the wheel, and that you will be able to anticipate what other drivers are going to do, so you can
be prepared and avoid accidents.
 Getting your driver’s license is a really great thing, and it is just one more step on your way to
adulthood. Remember, once you are a licensed driver, you have a whole new set of responsibilities.
You are not only responsible for yourself, but for anyone who happens to be in the vehicle with you
when you are driving, and you are responsible for those who are driving around you.

Defensive Driving tips:

1: Never use a cell phone while driving
2: Pay attention to all traffic signs
3: Never drive too closely behind another vehicle
4: Learn to drive in all weather conditions
 5: Give others the right of way

Driving Techniques

Before you get in the car and hit the road take some time to consider driving techniques for safe, confident and
comfortable steering. Basic Driving Concepts chapter includes information about such driving techniques as
staying in a driving lane, using the reference points when parking and backing up, and things you need to do
before starting to drive.

Get familiar with the use of lanes. There are some techniques that will help you recognize, which lane is
appropriate for your car and your type of driving. Always maintain a safe speed and beware of blind spots and
restricted areas. Following the speed limits is an important part of driving. The right speed can prevent
numerous mistakes. Be courteous on the road, and if you're going slower than the flow, let other drivers pass.
Move into a far right lane or use the turn out to let the car behind you move onward.

 Basic Driving Concepts

 Getting Started
 Use Of Lanes
 Speed
 Turning
 Parking
 Passing

Date Developed: Document No.

April 2020. Issued by:
SERVICING BRAKES
BLEEDING SYSTEM Developed by:
Revision # 07 0|Page
Romeo V. Honrada

Vehicle Safety Requirements

 Each person who operates equipment must have a valid driver’s license that is legally appropriate for
the type of vehicle they are operating.  Equipment operators must have in their possession a valid state license
where required.
 Equipment operators must make a pre-shift inspection in accordance with the manufacturer’s
instructions to ensure that all safety devices and operational features are in place and functioning properly. 
Noted deficiencies must be repaired by a qualified mechanic or technician prior to returning the equipment to
service.
 All mobile equipment must be provided with a windshield that is free of cracks or other conditions that
impede the vision of the operator.
 Operating and maintenance manuals must be kept in the cab of all mechanized equipment.
 The swing radius of all equipment that swings on a pivot should be delineated and protected if
necessary so that any pinch / crush hazards are protected from employees in the immediate area.  Barricades
must be provided to mark the work area when necessary.
 Whenever equipment is moved, tools and materials should be secured so as not to pose hazards to
either workers or the general public.
 Vehicles that have an obstructed view to the rear of the equipment must be equipped with a back-up
alarm (audible above the surrounding noise levels).

Backing Up, Moving Equipment, Spotters

 Where there are two or more persons in the vehicle, one person must exit the vehicle and act as the
observer/signal person whose sole function is to ensure that operator can back up safely without injury
to personnel or damage to surrounding equipment. 
 Properly trained and equipped flag persons/spotter must be used where necessary to ensure the safe
movement of vehicles, such as aerial lifts, or to control the flow of construction traffic and deliveries .

High Visibility Vests

 Personnel working in the vicinity of the equipment or in areas where they are exposed to vehicular
traffic must properly wear, at a minimum, high visibility (fluorescent green or orange) Class II safety
vests.  Hard hats are also required whenever the possibility exists to employees working in or around
machines which may pose potential overhead hazards .

Fire Prevention

 All mobile gasoline or diesel powered equipment must have a permanently mounted functional fire
extinguisher.  The engines of all vehicles and equipment must be shut down prior to fuelling.

Date Developed: Document No.

April 2020. Issued by:
Vehicle safety
requirements Developed by:
Revision # 08 0|Page
Romeo V. Honrada

Adjusting
Step 1

Position wheel chocks behind and in front of each of the front wheels. Loosen the lug nuts on the rear wheels
using the lug wrench, but don't remove yet. Raise up the rear of the vehicle using a jack and slip jack stands
under the vehicle next to each of the rear wheels for support. Lower the Tacoma onto the jack stands.
Step 2
Remove the rear lug nuts and wheels and set aside.
Step 3
Find the brake adjuster, which is a 4-inch spring. Use a flat-head screwdriver to turn the notched wheel attached
to the brake adjuster in a downward direction until the shoes touch the brake drum.
Step 4
Turn the wheel Step 1 in the other direction using the screwdriver. Do this for 15 clicks.
Step 5
Repeat Steps 3 and 4 for the other rear brake.
Step 6
Put the wheels back on and tighten the lug nuts. Raise the vehicle, remove the jack stands lower the vehicle to
the ground. Tighten the lug nuts all the way. Remove the wheel chocks.
Start the Tacoma and drive it slowly in reverse. Apply the brakes often as you do this to seat the shoes and
activate the brake adjusters.

 Items you will need

 4 wheel chocks
 Lug wrench
 Jack
 2 jack stands
 Flat-head screwdriver
 Ignition key

Date Developed: Document No.

April 2020. Issued by:

adjusting
Developed by:
Revision # 09 0|Page
Romeo V. Honrada

Setting Emergency and parking brakes

 The emergency brake, or parking brake as it's sometimes called, works independently from the brakes
that you tap to stop your car. It's that way on purpose so you have access to an alternative braking
system should your primary brakes fail.
 Your primary brakes work through a high-tech hydraulic system and are meant to slow your car to a
stop. The emergency brake, on the other hand, is designed to hold your car in place. However, if your
primary brakes fail, you can use the emergency brake to slow down and stop your car.
 The correct way is to stop your car with your primary brakes, set the emergency brake and then place
your car in park before turning off your engine.
 If you put the car in park and then release the brake pedal, the transmission holds the car in place. That
increases the wear and tear on it. Engaging the emergency brake first is easier on the transmission.
 When you're ready to leave, start your engine, press your primary brake, release the emergency brake
and shift into drive. Remember that driving with your emergency brake on can damage your car.
 Using the emergency brake every time you park gives your car added stability. For example, if your car
is hit while it's parked, the emergency brake decreases the chances of it rolling.
 Engaging the emergency brake also keeps it in good working order. Emergency brakes that aren't used
can rust, which makes them less likely to work properly in an emergency.

Date Developed: Document No.

Setting Emergency and April 2020. Issued by:
parking brakes
Developed by:
Romeo V. Honrada Revision # 10 0|Page