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46
BRAKE SYSTEMS
CHAPTER OVERVIEW
This chapter explains the principles of friction. The operating principles of hydraulic brake
systems are described, including power brakes and antilock brakes systems. General diagnostics, testing, and servicing of hydraulic brake systems are explained.
CHAPTER OBJECTIVES
Explain the basic principles of braking, including kinetic and static friction, friction
materials, application pressure, and heat dissipation.
Describe the components of a hydraulic brake system and their operation, including
brake lines and hoses, master cylinders, system control valves, and safety switches.
Perform both manual and pressure bleeding of the hydraulic system.
Briefly describe the operation of drum and disc brakes.
Inspect and service hydraulic system components.
Describe the operation and components of both vacuum-assist and hydraulic-assist
braking units.
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Brake Systems
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Chapter 46
16.
17.
18.
19.
20.
equal in all areas of the fluid regardless of the length of the lines. A larger master cylinder piston would result in lower, not higher, fluid pressure (pressure = force/area) and
less force applied to the brake shoes (force = pressure area).
c. Typically, master cylinders do not have a pressure relief valve.
a. Combination valves are replaced as a unit.
d. Neither technician is correct. The quick-take-up master cylinder is used on disc/
drum systems using low drag calipers and is not designed to increase braking power.
d. Neither technician is correct. When the bleeder valve is seized, the wheel cylinder
should be replaced. Using shop air to push fluid and air from the wheels to the master cylinder would increase the amount of air in the system, not remove it.
d. A leaking diaphragm in a vacuum-assist booster would provide little or no assist,
resulting in an extremely hard pedal.
TECH MANUAL
The following procedures are included in Chapter 46 of the Tech Manual:
1. Bench bleeding a master cylinder.
2. Pressure bleeding a hydraulic brake system.
3. Performing a power vacuum brake booster test.
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47
DRUM BRAKES
CHAPTER OVERVIEW
This chapter describes the design and operation of drum brakes and identifies the major
components used with drum brakes. It emphasizes service procedures such as road testing the brakes, drum brake inspection, drum refinishing, wheel cylinder inspection and
service, and adjusting parking brakes.
CHAPTER OBJECTIVES
Explain how drum brakes operate.
Identify the major components of a typical drum brake and describe their functions.
Explain the difference between duo-servo and nonservo drum brakes.
Perform a cleaning and inspection of a drum brake assembly.
Recognize conditions that adversely affect the performance of drums, shoes,
linings, and related hardware.
Reassemble a drum brake after servicing.
Explain how typical drum parking brakes operate.
Adjust a typical drum parking brake.
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Drum Brakes
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TECH MANUAL
The following procedures are included in Chapter 47 of the Tech Manual:
1. Inspecting and servicing duo-servo drum brakes.
2. Inspecting and servicing nonservo drum brakes.
3. Adjusting and replacing a parking brake cable.
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Chapter 47
7.
8.
9.
10.
False
A brake drum micrometer
a
True
0.90 inch (23 mm) or 0.30 inch (7 mm) less than the discard diameter
Duo-servo brakes have a double-piston wheel cylinder that activates the primary and
secondary brake shoes. The self-energizing force is transferred from one shoe to the
other with the wheel rotating in either direction.
Large domestic vehicles
They are used on smaller cars to reduce the chance of rear brake lockup.
c
Improperly adjusted parking brake, grease or fluid on linings, or improper size or type
of fittings
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48
DISC BRAKES
CHAPTER OVERVIEW
This chapter is devoted to disc brake design and function. It emphasizes inspection and
service of the disc brake components.
CHAPTER OBJECTIVES
List the advantages of disc brakes.
List disc brake components and describe their function.
Explain the difference between the three types of calipers commonly used on disc
brakes.
Describe the two types of parking brake systems used with disc brakes.
Describe the causes of common disc brake problems.
Explain what precautions should be taken when servicing disc brake systems.
Describe the general procedure involved in replacing disc brake pads.
List and describe five typical disc brake rotor problems.
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Chapter 48
II.
III.
IV.
V.
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Disc Brakes
197
10. d. Neither technician is correct. Air in the hydraulic system would cause a spongy,
not a hard, pedal. A pulsating brake pedal is most likely caused by a warped rotor,
not a restricted brake line.
11. d. The dust boot prevents moisture from entering the cylinder bore.
12. d. Neither technician is correct. It is not necessary to finish working on one wheel
before beginning work on the other. A safe air pressure to use for removing the caliper
piston is 30 psi (210 kPa), not 50 psi (345 kPa) as stated by Technician B.
13. d. Neither technician is correct. A visual examination of rotors is insufficient. They
should be measured for runout, parallelism, and minimum thickness before they are
reused. It is not considered normal for the inboard pad to wear faster than the outboard pad. Uneven wear often means the caliper is sticking and not giving equal pressure to both pads.
14. Light scratches and corrosion may be removed by cleaning with crocus cloth; the cylinder may also be honed if the manufacturer recommends it. Deep scratches or pitting
usually mean the caliper should be replaced.
15. c. Variation in rotor thickness is referred to as parallelism.
16. c. Both technicians are correct. Both procedures are recommended by various manufacturers.
17. a. Worn pad linings can damage a rotor. Hard spots on the rotor surface are the result
of heat developed during braking, not manufacturing defects.
18. b. Worn brake pad linings are more likely to cause noise, not a pulsating brake pedal.
19. b. A frozen bleeder screw may be drilled out and an insert installed. It may also be
possible to remove it by applying heat, but it should be removed and taken to a workbench for this procedure, not repaired on the car as recommended by Technician A.
20. d. Neither technician is correct. Never try to pry the piston out using a screwdriver.
Air pressure may be used to force the piston out of the bore, but it is supplied to the
fluid inlet, not through the bleeder screw bore. An attempt to supply air pressure
through the bleeder bore would necessitate blocking the fluid inlet passage. It is easier to close the bleeder screw and apply air at the inlet passage.
TECH MANUAL
The following procedures are included in Chapter 48 of the Tech Manual:
1.
2.
3.
4.
5.
False
Set the dial indicator on the rotors surface and rotate the rotor.
Thickness
Caliper piston seal
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Chapter 48
5. A floating caliper uses a single piston that forces the inboard pad against the rotor
and the resulting buildup of hydraulic pressure forces the outboard pad against the
other side of the rotor.
6. Worn disc brake pads, air in the system
7. Failure of the power brake booster or a failed vacuum line
8. c
9. a
10. A sticking caliper in a floating caliper system; a stuck piston in a fixed caliper
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49
ANTILOCK BRAKE, TRACTION
CONTROL, AND STABILITY
CONTROL SYSTEMS
CHAPTER OVERVIEW
This chapter explains the different antilock braking systems. Also covered are the components, service, diagnosis, and repair of these systems, as well as traction and stability
control.
CHAPTER OBJECTIVES
Explain how antilock brake systems work to bring a vehicle to a controlled stop.
Describe the differences between an integrated and a nonintegrated antilock brake
system.
Briefly describe the major components of a two-wheel antilock brake system.
Briefly describe the major components of a four-wheel antilock brake system.
Describe the operation of the major components of an antilock brake system.
Describe the operation of the major components of automatic traction and stability
control systems.
Explain the best procedure for finding ABS faults.
List the precautions that should be followed whenever working on an antilock
brake system.
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Chapter 49
III.
IV.
V.
VI.
VII.
VIII.
8. Modulator Unit
9. Solenoid Valves
10. Valve Block Assembly
11. Wheel Circuit Valves
B. Electrical/Electronic Components
1. ABS Control Module
2. Brake Pedal Sensor
(a) Data Link Connector (DLC)
(b) Diagnostic Trouble Code (DTC)
3. Indicator Lights
4. Lateral Acceleration Sensor
5. Pressure Switch
6. Pressure Differential Switch
7. Relays
8. Toothed Ring
9. Wheel-Speed Sensor
Hint: Show some printouts of DTCs and describe how they are used by
technicians. Pass around a variety of ABS electrical components. Point
out which components would be associated with which DTCs.
Types of Antilock Brake Systems
Hint: Show examples of integral assemblies and nonintegral hydraulic
modulators. Compare the differences in function.
A. Two-Wheel Systems
B. Full (Four-Wheel) Systems
ABS Operation
A. Two-Wheel Systems (Nonintegral)
B. Four-Wheel Systems (Nonintegral)
1. Operation
2. Modulator Assembly
3. Self-Diagnosis
C. Four-Wheel Systems (Integral)
1. General Motors Electromagnetic Antilock Brake Systems
D. Other Brake System Controls
Automatic Traction Control
Automatic Stability Control
Antilock Brake System Service
A. Safety Precautions
B. Relieving Accumulator Pressure
Diagnosis and Testing
A. Prediagnostic Inspection
B. Visual Inspection
C. Test Drive
D. Self-Diagnostics
Hint: Assign the students to retrieve DTCs.
E. Testers and Scanning Tools
F. Testing Components with ABS Scan Tools
G. Solenoid Leak Test
H. Testing Components with a Lab Scope
Hint: Demonstrate the wheel speed sensor voltage pattern on a lab scope.
I. Component Replacement
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Chapter 49
20. a. Some systems use a lateral acceleration sensor in addition to the wheel-speed
sensors. Traction control applies one wheel when it attempts to spin and lose traction; stability control applies one brake to keep the vehicle going in the direction in
which it is being steered.
TECH MANUAL
The following procedures are included in Chapter 49 of the Tech Manual:
1. Performing ABS tests using a scan tool.
2. Monitoring the operation of the ABS solenoids using a lab scope.
3. Testing a wheel-speed sensor and adjusting its gap.
SECTION 8
Answers to ASE Prep Questions
1.
2.
3.
4.
5.
a
c
d
a
b
6.
7.
8.
9.
10.
a
b
c
c
d
11.
12.
13.
14.
15.
c
a
c
a
a
16.
17.
18.
19.
20.
d
b
a
b
b