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Brake System Diagnosis and Repair
Brake System Diagnosis and Repair
Brake System Diagnosis and Repair
Russell Krick
Publisher
(11 Topics)
On-Board Diagnostics
Self-diagnostics may be available on
vehicles, especially those equipped
with anti-lock brake systems
Connect a scan tool to the diagnostic
connector
Read any stored diagnostic trouble
codes
Check the scan data for anti-lock brake
operating values
Goodheart-Willcox Co., Inc.
Brake Vibration
Shows up as a chatter, pulsation, or
shake in the brake pedal or steering
wheel
Occurs only when the brakes are
applied
Front brake problems may be felt
mostly in the steering wheel
Pulsation in the brake pedal may be
caused by brake problems at any wheel
Goodheart-Willcox Co., Inc.
Brake Vibration
Possible causes:
warped disc
out-of-round brake drum
hard spots on the disc or drum
Grabbing Brakes
Brakes apply too quickly, even with
light brake pedal application
Possible causes:
malfunctioning brake booster
brake fluid or grease on the linings
worn brake linings
faulty metering valve
mechanical problem in the wheel brake
assembly
Goodheart-Willcox Co., Inc.
Pulling Brakes
The vehicle veers to the right or left
when the brakes are applied
Possible causes:
seized caliper or wheel cylinder piston
grease or fluid-coated lining
leaking cylinder
faulty automatic adjuster
brake lining dust in a drum brake
assembly
Goodheart-Willcox Co., Inc.
Dragging Brakes
The brakes remain partially applied
when the brake pedal is released
To detect dragging brakes, carefully
feel each brake assembly
dragging brakes will be abnormally hot
Dragging Brakes
Possible causes:
seized wheel cylinder pistons or parking
brake cables
overadjusted parking brake or master
cylinder push rod
weak return springs
master cylinder problems
No Brake Pedal
Very dangerous condition in which the
brake pedal moves to the floor with no
braking action
Possible causes:
hydraulic system leak that causes the
loss of the brake fluid
faulty master cylinder
Brake Warning
Light On
Indicates either an internal leak
(master cylinder) or an external leak
Unequal pressure in the dual master
cylinder system has caused the
warning light switch to shift to one side
Braking Noise
Noises include grinding sounds,
squeaks, or rattles
Metal-on-metal grinding sound when
braking
caused by worn brake linings
Braking Noise
Squeak when braking
caused by glazed or hardened brake
linings, dry brake drum backing plate, or
wear indicator rubbing on the rotor
Rattles
caused by a missing anti-rattle clip or
loose parts
Brake System
Problems
Brake Pedal
Measurements
Brake Pedal
Measurements
Hydraulic Booster
Service
Check all the hydraulic lines for signs
of leakage
If the booster is inoperative, check the
power steering fluid level
Most boosters are not serviceable
without special equipment and
procedures
Master Cylinder
Removal
Disconnect the brake lines using a line
wrench
Unbolt the master cylinder from the
booster or cowl
On a vehicle without a power-assist
booster, disconnect the push rod from
the brake pedal assembly
Master Cylinder
Rebuild
Following the service manual
procedures, drain the fluid and
disassemble the unit
Honing may be used to remove minor
corrosion or pits from the cylinder
surface must be in perfect condition
Master Cylinder
Rebuild
Bench Bleeding
Installing a Master
Cylinder
Bolt the master cylinder to the cowl or
booster
Check the adjustment of the push rod if
specified
Install the brake lines with the fittings
lightly tightened
Installing a Master
Cylinder
Bleed the air from the fittings
Tighten the fittings
Fill the reservoir with fluid
Check brake pedal feel and road test
the vehicle
Manual Bleeding
Attach one end of a hose to a bleeder
screw and place the other end in a jar
containing brake fluid
Have another technician apply light
foot pressure on the brake pedal
Open the bleeder screw while watching
for air bubbles flowing from the hose
Manual Bleeding
Close the bleeder screw
Have your helper release the brake
pedal
Repeat the steps until the flow from the
hose is clear and free of bubbles
Perform the operation on all of the
brake assemblies, starting farthest
from the master cylinder
Manual Bleeding
Pressure Bleeding
Pressure Bleeding
Fill the tank with fluid
Charge the tank with 1015 psi (69103 kPa)
of air pressure
Fill the master cylinder with fluid
Install the adapter and hose on the master
cylinder
Open the valve in the hose
Pressure Bleeding
Attach one end of a hose to a bleeder
screw and place the other end in a jar
containing brake fluid
Open the screw until the fluid entering
the jar is clear of bubbles
Pressure Bleeding
Flushing a Brake
System
Extends the life of the brake system
components
Done by pressure bleeding all the old
fluid out of the system
Removes contamination such as dirt,
rust, corrosion, oil, or moisture
Bleed each wheel brake assembly until
clean fluid flows from the bleeder screw
Goodheart-Willcox Co., Inc.
Rebuilding a Caliper
To remove the piston, apply low air
pressure
Rebuilding a Caliper
Rebuilding a Caliper
Rebuilding a Caliper
Rebuilding a Caliper
Rebuilding a Caliper
Inspect the piston for wear or damage
Clean all parts in an approved cleaner
Coat the parts in brake fluid
Rebuilding a Caliper
Rebuilding a Caliper
Measuring Disc
Runout
Runout is the amount of side-to-side
movement measured near the outer
edge of the friction surface
Typical maximum runout:
0.004" (0.10 mm)
Measuring Disc
Runout
Measuring Disc
Thickness
The thickness will decrease as the disc
wears
The minimum thickness may be printed
on the side of the disc
If the disc thickness is under
specifications, replace the disc
Measuring Disc
Thickness
Resurfacing a Disc
Involves machining a discs friction
surfaces on a brake lathe to correct
runout, thickness variation, or scoring
Mount the disc on the brake lathe
according to the lathe manufacturers
recommendations
With the machine feeds and controls
set properly, machine smooth surfaces
on the disc
Goodheart-Willcox Co., Inc.
Resurfacing a Disc
Always read the
operating manual
before using a brake
lathe
Resurfacing a Disc
Resurfacing a Disc
Brake Lathe
This lathe has a large
cover to protect
operators and others
in the shop from
flying debris
On-Car
Brake Lathe
A stand-mounted
electric motor
rotates the disc
Disc Brake
Reassembly
After installing the rotor, fit the caliper
assembly into place
High-temperature silicone is used on
the backs of the pads to help prevent
brake rattle and squeal
Apply a small amount of silicone
grease to the caliper mounting bolt
threads
Disc Brake
Reassembly
Disc Brake
Reassembly
Disc Brake
Reassembly
The rotor and
lining surfaces
should be
perfectly clean
after repairs
Drum Brake
Disassembly
Drum brake
components
Drum Brake
Disassembly
Drum Brake
Disassembly
Use a hold-down
spring tool to remove
the hold-down springs
Permission granted to reproduce for educational use only
Drum Brake
Disassembly
Lift the brake shoes off the backing
plate
Remove the automatic adjuster
mechanism
Clean the backing plate
Servicing Wheel
Cylinders
A cylinder must be replaced or rebuilt if
it shows signs of leakage or sticking
Many shops service the wheel
cylinders anytime the linings are
replaced
Wheel cylinder rebuilding involves
honing the cylinder and replacing the
rubber cups and boots
Goodheart-Willcox Co., Inc.
Brake Drum
Resurfacing
Brake Drum
Resurfacing
Use the correct
collars and hubs
to secure the
drum to the lathe
shaft
Brake Drum
Resurfacing
The drum
Typically, a drum
should not be machined diameter is often
stamped on the
more than 0.060"
(1.5 mm) oversize
drum
Goodheart-Willcox Co., Inc.
Use a drum
micrometer to
measure the
diameter
Permission granted to reproduce for educational use only
Drum Brake
Reassembly
Clean the wheel bearings
Inspect the bearings for wear or
damage
Pack the bearings with grease and
install new grease seals
Drum Brake
Reassembly
Drum Brake
Reassembly
Preadjusting Drum
Brakes
Ensures proper initial brake system
operation
Fit a brake adjusting gauge into the
brake drum
Set the gauge for the inside diameter
of the drum
Fit the gauge over the brake shoes
Adjust the brake until the linings touch
the gauge
Goodheart-Willcox Co., Inc.
Preadjusting
Drum Brakes
Fitting the gauge into
the brake drum
Preadjusting Drum
Brakes
Another method of preadjusting the
brakes:
use a brake spoon to turn the star wheel
turn the wheel until the brake drum drags
slightly when rotated by hand