1

Basics
Define the task of having Braking System in a vehicle. PDI

Maintenance

Transmission
Engine

Suspension
Write down the different types of braking systems used in automobile. (Ex – Mechanical Brake)
Steering

Brakes
Wheels
Alignment
 2
Braking Circuit
Write down the name of components used in Hydraulic Braking system of a passenger car. PDI

Maintenance

Transmission
Engine

Suspension
Name different types of Brake circuit configuration used in a passenger car.
Steering

Brakes
Wheels
Alignment
 3
Disc Brake & Drum Brake
Note down the advantage & dis-advantage between the drum brake and the disc brake. PDI

Maintenance

Transmission
Engine

Suspension

Steering

Brakes
Wheels
Alignment
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Brake Fluid
What is brake fading? PDI

Maintenance

Transmission

Note down the characteristics of the Brake fluid.

Engine

Suspension

Steering

Brakes
What is meant by term wet boiling point of brake fluids? What is the difference between DOT4 &
DOT4+ Wheels
Alignment
 5
Brake Pad
Define the characteristics of the Brake Pad. PDI

Maintenance

Transmission

Which material is used for making the Brake Pad.

Engine

Suspension

Steering

Brakes
Wheels
Alignment
 6
Brake Bleeding
Write down the procedure, step by step regarding the replacement of the brake fluid. PDI

Maintenance

Transmission
Engine

Suspension

Steering

Brakes
Wheels
Alignment
 7
What are the components of a hydraulic brake circuit.
PDI

Maintenance

Transmission
Describe the working of the brake master cylinder in detail.
Engine

Suspension

Steering
What is Tandem master cylinder & how it is advantageous?
Brakes
Wheels
Alignment
 8
Study the working of the brake booster (Mention document number) PDI
Explain the working of the brake booster in brief using the pictures
Maintenance

Transmission
Engine

Suspension

Why do diesel engine require a vacuum pump? Steering

Brakes
Wheels
Why is a brake booster required in the car?

Alignment
 9
1. Why do we need a Braking system in a vehicle?
PDI

2. Which different types of Braking systems are used in a vehicle?

Maintenance

Transmission
Engine
3. What is the task of Brake pad used in the Hydraulic breaking system?
Suspension

Steering
4. When the Brake pad Thickness is measured & which special tool is required for it?
Brakes
Wheels
5. When does the Brake pad needs replacement?
Alignment
 10
6. Why generally front brake pads are larger than the rear brake pads?
PDI

Maintenance
7. Why retaining springs are provided on the brake pads?
Transmission
Engine

8. What is the task of Brake disc used in the Hydraulic Braking system? Suspension

Steering

9. Name the different types of brake disc used in passenger cars & its Brakes
advantage?
Wheels
Alignment
 11
10. Which all circumstances will you replace the brake disc?
PDI

Maintenance
11. Note down the precaution to be taken while handling a Ceramic & composite
brake disc
(Refer WIS doc. AH 42. 10-P-9406-13A & 12LF)
Transmission
Engine

Suspension
12. What is the task of Tandem Master Cylinder used in the Hydraulic Braking
system?
Steering

Brakes
13. What do you know about the following types of brake circuit configuration? Wheels
Alignment
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14. Disassemble the brake Master cylinder &name the different parts of it ; also
explain how the pressure gets developed in the Master cylinder? PDI

Maintenance

Transmission
15. What are the advantages of having Disc brakes?
Engine

Suspension

Steering
16. What is the task of brake caliper? Brakes
Wheels
Alignment
 13
17. Which different types of Brake calipers do you know?
PDI

Maintenance

Transmission
18. Remove & disassemble the Floating Caliper. Explain the braking
operation. Engine

Suspension

Steering

Brakes
19. How the air gap is maintained between Brake pad & Brake disc?
Wheels
Alignment
 14
20. How will you measure the lateral out of the Brake disc?
PDI

Maintenance

Transmission
21. Follow the WIS document & describe how will you remove & install the Brake Master
cylinder & Floating caliper?
Engine

Suspension

Steering

22. For what reasons will you replace the Brake Master cylinder? Brakes
Wheels
Alignment
 15
23. Refer WIS document & define what special instruction to be followed while installing
the Floating caliper? PDI

Maintenance

24. What is the task of vacuum brake booster & name the different types?
Transmission
Engine

Suspension
25. For what reason, the one way valve is provided in the brake booster? Steering

Brakes
26. How will you test vacuum brake booster is working or not? Wheels
Alignment
 16
27. How will you test the working of defective one way valve (without using vacuum gauge)?
PDI

Maintenance

Transmission
Engine

28. State the properties of Hydraulic Brake Fluid? Suspension

Steering

Brakes
Wheels
Alignment
 17
( 1) Measure & note down the thickness of Front & Rear Brake Pad. ( with and without
pad removal) PDI
 
With Brake Pad Maintenance
Fr. Rh: ___________

Fr. Lh: ___________

Transmission
Re. Rh: ___________
Re. Lh: ___________ Engine
 
  Suspension
Without Brake Pad
Fr. Rh: ___________ Steering
Fr. Lh: ___________
Re. Rh: ___________ Brakes
Re. Lh: ___________
  Wheels
 ( Refer to WIS Doc No AP 42.10 - P - 4253 03 A )
Alignment
 18
(2) Note down the formula used to calculate the duration of front & rear brake pad ?
( Refer to WIS Doc No AP 42.10 - P - 4253 03 EW ) PDI

Maintenance

Transmission
Engine

Suspension

Steering

Brakes
Wheels
Alignment
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(3) At what remaining thickness of brake pad, the warning lamp in the ICM comes “ ON”
& how many kilometers the vehicle can still be driven after that? PDI

Maintenance

Transmission
Engine

Suspension
(4) Note down the reasons for uneven brake pad wear pattern
Steering

Brakes
Wheels
Note: 1. Observe the retaining spring – not corroded, not bend.
2. Always replace brake pad in pair & on both side of same axle. Alignment
 20
(5) Explain the steps to be followed while replacing brake fluid, using ‘Pressure Bleeding
Method’ ? PDI
(Refer WIS Doc No : AR 42.10 – P – 0010 LW )
Maintenance

Transmission
Engine

Suspension
(6) What precaution must be taken while handling brake fluid? Steering
(Refer WIS Doc No: AH42.50 - P - 0001 - 01 A)
Brakes
Wheels
Alignment
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(7) Measure the thickness of Front & Rear brake disc & note the Actual Vs. Specified Values
( Refer WIS Doc No.: AP 42.10 – P – 4252 CW) PDI

Maintenance

Transmission
Engine
(8) Under what circumstances will you decide to replace the brake disc?
(Refer WIS Doc No.: AP 42.10-P-4256EW) Suspension

Steering

(9) How will you check for wear & evaluate the condition for damage to ceramic disc? Brakes
(Refer WIS Doc No.: AP 42.10-P-4258AC)
Wheels
Alignment
 22
(10) Explain step by step removal & installation procedure for front & rear brake caliper?
(Refer WIS Doc No.: AR 42.10 - P - 0225CW & 0250 CW) PDI

Maintenance

Transmission

(11) How will you adjust Mechanically operated parking brake? Engine
(Refer WIS Doc No.: AR 42.20-P-0540CW & 0523CW)
Suspension

Steering

Brakes
Wheels
Alignment
 23
(12) How will you test the malfunction in the Brake Booster?
(Refer WIS Doc No.: AR 43.10-P-0325CW) PDI

Maintenance

Transmission
Engine

Suspension

Steering
(13) How will you test the check valve used for Brake Booster?
(Refer WIS Doc No.: AR 43.10-P-0023CW)
Brakes
Wheels
Alignment
 24
Review Questions
A two-circuit brake can be recognized … • pressure spring and the primary cup seal. PDI
• on the 2 pistons in the brake caliper. filling bores and the secondary cup seal.
on the 2 wheel brake cylinders per wheel. • primary cup seal and the main cylinder Maintenance
piston.
• on the main cylinder.
• on the assembly of the wheel brake.
• bed-stop bushing and the intermediate Transmission
piston.
Which statement about the main cylinder is
The left rear wheel brake is defect of a
correct?
double brake circuit with diagonal Engine
• A uniform pressure is created in both brake separation. The brake fails …
circuits.
• on all four wheels. Suspension
The braking pressure of the rear axle has to
be greater than that of the front axle. only on the left rear wheel.
• The braking pressure of the front axle has to • on both rear wheels. Steering
be greater than that of the rear axle.
• on the left rear wheel and on the front right
• The pressure has to be reduced slowly when
disengaging the brake.
wheel. Brakes
The filling washer of the main cylinder is
positioned between … Wheels
Alignment
 25
Review Questions
Which advantages does the drum brake have
over the disc brake?
a. Brake pads are usually easier to change.
b. They are better vented.
c. They have a higher self reinforcement.
d. They have no Fading and a good venting.
What is understood by brake fading?
e. Improvement of the braking action.
f. Non uniform operation of the brakes.
g. Dwindling of the braking operation because
of the reduction of the frictional value of the
brake pads.
h. Inclined pulling of the brake.
How is the servo operation of the drum brake
reached?
i. Through the use of large wheel cylinders.
j. Through the assembly of brake power
servos.
k. Through the friction which attracts the on
running brake shoes in the drum
l. Through the assembly of a double operating
wheel brake cylinder.
Which advantage do disc brakes have over
drum brakes?
a. They have a large servo operation.
PDI
b. They are protected against dirt.
c. The pads are easy to change.
d. They have a low pad wear.
Maintenance
How is the return position of the brake piston
carried out after loosening the brake? Transmission
• through the brake fluid
only through the wedge springs
• through the sealing ring and wedge springs Engine
• through the piston return position
How can it be recognized when the brake disc
pads are worn out?
Suspension
• The wheels flatten when braking.
The brake fluid level has sunk.
• It has to be braked harder.
Steering
• The pedal distance is further.
Brakes
Wheels
Alignment
 26
Review Questions
PDI
What effect do the different brake disc • Wet boiling point at 2% water contents
thicknesses have when braking?
• Wet boiling point at 3,5% water Maintenance
• A large tendency to vapor bubble contents
formation. Transmission
• Wet boiling point at 100% atmospheric
The wheels tend to Flatter. humidity
•The brake pedal and steering wheel • Maximal Wet boiling point Engine
vibrate.
Which brake pad materials are used for
•A low self adjustment of the pads. brake pads? Suspension
How large is the clearance of the piston • Asbestos fibres with frictional materials
of a disc brake?
• Grafitated plastic pads with steel wool Steering
• approx. 0,001 mm •Organic fibres with a low frictional value
approx. 0,15 mm
• Carbons with aramid fibres Brakes
• approx. 1 mm
• approx. 1,5 mm Wheels
What is meant by the term wet boiling
point of brake fluids?
Alignment
 27
Review Questions
Which characteristics apply to brake liquids?
• Age resistant, high boiling point
• Chemically neutral behavior, compressible
• High boiling point, hygroscopic
• Low compaction, low solidifying point
Which faults of the brake system can be
established with pressure apparatus?
• Incorrectly set brakes
• Leakages in the hydraulic brake system
• Deformed brake pipes and widened brake
hoses
• Faulty brake discs and brake drums
How is the assistant force of the pneumatic
power braking system created?
• through hydraulic pressure onto a membrane PDI
• through the pressure difference of under
pressure and external air onto a membrane Maintenance
• through compressed air which acts upon the
main cylinder
Transmission
• the uniform pressure of a membrane
Which pressure relationship are present with
an vacuum braking force strengtheners in its Engine
release position?
• Under pressure is present in the under Suspension
pressure chamber and external air pressure in
the working chamber.
• External air is present in the under pressure Steering
and working chamber.
• Under pressure is present in the under
pressure and working chamber.
Brakes
• External air pressure is present in the under
pressure chamber and under pressure in the Wheels
working chamber.
Alignment