Chap 69

start
Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition ©©2008

2009Pearson
PearsonEducation,
Education,Inc.
Inc.
By James D. Halderman Pearson
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
OBJECTIVES:
After studying Chapter 69, the reader should
be able to:
• Prepare for ASE Brakes (A5) certification test
content area “A” (Hydraulic System Diagnosis
and Repair).
• State Pascal’s Law.
• Describe the function, purpose, and operation
of the master cylinder.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
OBJECTIVES:
After studying Chapter 69, the reader should
be able to:
• Explain how hydraulic force can be used to
supply high pressures to each individual wheel
brake.
• Describe the process of troubleshooting master
cylinders and related brake hydraulic
components.
• Explain how a quick take-up master cylinder
works.

2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
KEY TERMS:
bore master cylinder • breather port • bypass port •
bypassing
compensating port
diagonal split master cylinder • dual split master cylinder
fast-fill master cylinder • filler port
hydraulic system • master cylinder
Pascal’s Law • pedal free play • pedal height • pedal

reserve distance • piston assemblies
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
KEY TERMS:
quick take-up master cylinder
replenishing port
self-apply • step-bore master cylinder
vent port

2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
HYDRAULIC PRINCIPLES
In addition to mechanical advantage provided by leverage, all
vehicles use hydraulic pressure to increase brake application force.
All braking systems require that a driver’s force is transmitted to
the drum or rotor attached to each wheel. The force exerted on the
brake pedal varies due to strength and size of the driver.
Figure 69–1 Hydraulic brake lines transfer the
brake effort to each brake assembly attached
to all four wheels. Engineers design brake systems
to require less than 150 lb of
force (68 kg) from the driver,
yet provide the force necessary
to stop a heavy vehicle from
high speed.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
NONCOMPRESSIBILITY OF LIQUIDS
Hydraulic systems use liquids to transmit motion. For all
practical purposes, a liquid cannot be compressed.
No matter how much pressure or

force is placed on a quantity of
liquid, its volume will remain
the same.
Figure 69–2 Because liquids cannot be
compressed, they are able to transmit
motion in a closed system.
This fact enables liquids in a

closed system to transmit
motion.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Liquids cannot be compressed, but any air trapped in the system
can be compressed. The hydraulic system is air-contaminated.
Even though piston A is moved 1 in., piston B will not move if the
load on it is greater than the pressure of the air in the system.
Figure 69–3 Hydraulic systems must be free
of air to operate properly.
If the load on piston B is 50

pounds per square inch (psi),
the movement of piston A
must compress the air in the
system to that same pressure
before piston B will move.
A brake system must be air
free or there will be serious
problems.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
PASCAL’S LAW
The hydraulic principles that permit a brake system to function were discovered by a French physicist,
Blaise Pascal (1632–1662). Pascal’s Law states that “when force is applied to a liquid confined in a
container or an enclosure, the pressure is transmitted equal and undiminished in every direction.”
Assume a force of 10 lb is exerted on a piston with a surface area of 1 square inch (sq. in.). Since this force
measured in lb or Newtons (N) is applied to a piston with an area measured in square inches (sq. in.), the
pressure is the force divided by the area or “10 pounds per square inch” (psi).
It is this “pressure” that is transmitted, without loss, throughout the entire hydraulic system. See Figure 69–
4.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Figure 69–4 A one-pound force exerted on a small piston in a sealed system transfers the
pressure to each square inch throughout the system. In this example, the 1-lb force is able to
lift a 100-lb weight because it is supported by a piston that is 100 times larger in area than the
small piston.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
If you know two out of the three factors, you can calculate the
other using this formula:
See the formula on Page 826 of your textbook.
A practical example involves a master cylinder with a piston area of

1 sq. in., and one wheel cylinder with an area of 1 sq. in., and one
wheel cylinder with a piston area of 2 sq. in. See Figure 69–5.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Figure 69–5
The amount of force on the piston is the result of pressure multiplied by the surface area.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
The real “magic” of a hydraulic brake system is the fact that
different forces can be created at different wheel cylinders. More
force is necessary for front brakes than for rear brakes because, as
the brakes are applied, the weight of the vehicle moves forward.
Larger (area) pistons are used in wheel cylinders (calipers, if disc

brakes) on front wheels to increase force to apply front brakes.
Not only can hydraulics act as a “force machine” (by varying

piston size), but the hydraulic system also can be varied to change
piston stroke distances.
On a typical vehicle, a driver-input force of 150 lb (660 Newtons)

is boosted both mechanically (through the brake pedal linkage)
and by the power booster to a fluid pressure of about 1700 psi
(11,700 kPa).
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
NOTE: During a typical brake application, only about 1 teaspoon (5 ml
or cc) of brake fluid actually is moved from the master cylinder and into
the hydraulic system to cause the pressure buildup to occur.
With a drum brake, the wheel cylinder expands and pushes the brake
shoes against a brake drum.
The distance the shoes move is

about 0.005–0.012 in. (5 to 12
thousandths of an inch) (0.015–
0.30 mm).
Figure 69–6 Drum brake illustrating

the typical clearance between the
brake shoes (friction material) and
the rotating brake drum represented
as the outermost black circle.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
With a disc brake, brake fluid pressure pushes on the piston in the
caliper a small amount and causes a clamping of the disc brake pads
against both sides of a rotor (disc).
Figure 69–7 The brake pad (friction material) is

pressed on both sides of the rotating rotor by
the hydraulic pressure of the caliper.
The typical distance the pads

move is only about 0.001–0.003
in. (1-to 3-thousandths-of an
inch) (0.025–0.076 mm).
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Hydraulic Pressure and Piston
Size If a mechanical force of 100 lb
is exerted by the brake pedal
pushrod onto a master cylinder
piston with 1 sq. in. of surface area,
the equation reads:
The result in this case is 100

psi of brake system hydraulic
pressure.
Figure 69–8 Mechanical force and the master
cylinder piston area determine the hydraulic
pressure in the brake system.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
However, if the same 100-lb force is applied to a master cylinder
piston with twice the area (2 sq. in.), the equation will read:
Doubling the area of the master cylinder piston cuts the hydraulic
system pressure in half. Conversely, if the same 100-lb force is
applied to a master cylinder piston with only half the area (0.5 or
1/2 sq. in.), the equation will show the system pressure is doubled:
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Application Force and Piston Size
While size of the master cylinder
piston affects hydraulic pressure of
the entire brake system, weight shift
and bias require the heavily loaded
front brakes receive much higher
application force than the lightly
loaded rear brakes.
Pascal states that pressurized liquid

in confined space acts with equal
pressure on equal areas.
100 psi from the master cylinder
will result in 100 psi of friction
assembly application force.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Figure 69–10 Differences in brake
caliper and wheel cylinder piston
area have a major effect on brake
application force.
It is piston surface area, not

diameter, that affects force.
In the simple brake system,

the pedal and linkage apply
a 100-lb force on a master
cylinder piston with an area
of 1 sq. in.
This results in a pressure of
100 psi throughout the
hydraulic system.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Piston Size versus Piston Travel In disc brakes, mechanical
force available to apply the brakes is four times greater because
of size differences between master cylinder and caliper pistons.
Some hydraulic energy is converted into increased mechanical
force. The tradeoff is the larger caliper piston with greater force
will not move as far as the smaller master cylinder piston.
Hydraulic energy converted into mechanical motion is decreased.
The relative movement of pistons

within the brake system can be
calculated with the following
equation:
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Figure 69–11 The increase in application force created by the large brake caliper piston is
offset by a decrease in piston travel.
The results show that

if the master cylinder
piston stroke is 1 in.,
the caliper piston will
move only 1/4 inch.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Figure 69–12 The decrease in application force created by a small wheel cylinder piston is
offset by an increase in piston travel.
If caliper piston area

were reduced to 2 sq. in.,
application force would
increase to only 200 lb,
the caliper piston would
travel 1/2 inch for a 1 in.
master cylinder stroke.
With a dual- piston

cylinder, the total travel
is divided between the
two pistons.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Hydraulic Principles and Brake Design When a brake system
is designed, the hydraulic relationships discussed above play a
major part in determining the sizes of pistons within the system.
The piston sizes selected must move enough fluid to operate the
wheel cylinder and brake caliper pistons through a wide range of
travel, while at the same time they must create enough application
force to lock the wheel friction assemblies.

2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
MASTER CYLINDERS
The master cylinder is the heart of the entire braking system. No
braking occurs until the driver depresses the brake pedal. The
brake pedal linkage applies the force of the driver’s foot into a
closed hydraulic system.
Master Cylinder Reservoirs Most vehicles built since the early

1980s are equipped with see-through master cylinder reservoirs,
which permit owners and service technicians to check the brake
fluid level without having to remove the top of the reservoir.
Some countries have laws that require this type of reservoir.
See Figure 69–13.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Figure 69–13 Typical master cylinder showing the
reservoir and associated parts. The reservoir
diaphragm lays directly on top of the brake fluid,
which helps keep air from the surface of the brake
fluid because brake fluid easily absorbs moisture
from the air.
Reservoir capacity is great enough

to allow for the brakes to become
completely worn out and still have
enough reserve for safe operation.
The typical capacity of the entire

braking system is usually 2 to 3
pints (1 to 1.5 liters).
Vehicles equipped with four-wheel

disc brakes usually hold 4 pints (2
liters) or more.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Master Cylinder Reservoir Diaphragm The entire system is
filled with brake fluid to the “full” level of the master cylinder
reservoir, which is vented to the atmosphere so the fluid can
expand and contract without difficulty as would be the case if the
reservoir were sealed.
CAUTION: The master cylinder should never be filled higher than the
recommended full mark to allow for fluid expansion that occurs normally
when the brake fluid gets hot due to the heat generated by the brakes.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Being open to the atmosphere allows the possibility of moisture-
laden air coming in contact with the brake fluid! Moisture in the
air is readily and rapidly absorbed into the brake fluid because
brake fluid has an affinity (attraction) to moisture (water).
Master cylinders use a rubber diaphragm or floating disc to help

seal outside air from direct contact with brake fluid. As the brake
fluid level drops due to normal disc brake pad wear, the rubber
diaphragm also lowers to remain like a second skin on top of the
brake fluid.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Whenever adding brake fluid, push the rubber diaphragm back
up into the cover. Normal atmospheric pressure will allow the
diaphragm to return to its normal position on top of the fluid.
Whenever servicing a brake

system, be sure to check
the vent hole is clear on
the cover to allow air to get
between the cover and the
diaphragm.
Figure 69–14 All master cylinders should

have a vent hole on the outside cover that
allows air between the cover and the rubber
diaphragm.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Don’t Fill the Master Cylinder Without
Seeing Me!
The boss explained to the beginning tech that there are two reasons why the
customer should be told not to fill the master cylinder reservoir when the
brake fluid is down to the “minimum” mark, as shown here.
1. As the brakes wear, the brake piston moves outward to maintain the
same distance between friction materials and the rotor. As disc
brake pads wear, brake fluid level goes down to compensate.
2. If the master cylinder reservoir is low, there may be a leak that
should be repaired.
If a customer notices that brake fluid is low
in the master cylinder reservoir, the vehicle
should be serviced—either for new brakes
or to repair a leak.
Figure 69–15 Master cylinder with brake fluid level at the

“min” (minimum) line.

2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Is Bigger Better? - Part 1
A vehicle owner wanted better braking performance from his off-road race
vehicle. Thinking that a larger master cylinder would help, a tech replaced
the original 1-in.-bore-diameter master cylinder with a larger master
cylinder with a 1 1/8-in.-bore-diameter master cylinder. After bleeding the
system, the tech was anxious to test-drive the “new” brake system. During
the test-drive the tech noticed that the brake pedal “grabbed” much higher
than with the original master cylinder. This delighted the tech.
The owner of the vehicle was also delighted until he tried to stop from
highway speed. The driver had to use both feet to stop! The tech realized,
after the complaint, that the larger master cylinder was able to move more
brake fluid, but with less pressure to the wheel cylinders. The new master
cylinder gave the impression of better brakes because the fluid was moved
into the wheel cylinders (and calipers) quickly, and the pads and shoes
contacted the rotor and drums sooner because of the greater volume of
brake fluid moved by the larger pistons in the master cylinder.

2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Is Bigger Better? - Part 2
To calculate the difference

in pressure between the
original master cylinder
and the larger replacement,
the tech used Pascal’s Law
with the following results:
The difference in pressure is 119 PSI less with the larger master cylinder
(573 - 454 = 119). The stopping power of the brakes was reduced because
the larger diameter master cylinder piston produced lower pressure (the
same force was spread over a larger area and this means that the
pressure [PSI] is less). All master cylinders are sized correctly from the
factory for correct braking effort, pressure, pedal travel, and stopping
ability. A tech should never change sizing of any hydraulic brake
component on a vehicle!
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Too Much is Bad
Some vehicle owners or inexperienced service people may fill the master cylinder to
the top. Master cylinders should only be filled to the “maximum” level line or about
1/4 in. (6 mm) from the top to allow room for expansion when the brake fluid gets hot
during normal operation.
If the master cylinder is filled to the top, the expanding brake fluid has no place to
expand and the pressure increases. This increased pressure can cause the brakes
to “self-apply,” shortening brake friction material life and increasing fuel consumption.
Overheated brakes can result and the brake fluid may boil, causing a total loss of
braking.

2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
MASTER CYLINDER OPERATION
The master cylinder is the heart of any hydraulic braking system.
Brake pedal movement and force are transferred to the brake fluid
and directed to wheel cylinders or calipers.
Figure 69–16 The typical brake pedal is

supported by a mount and attached to the
pushrod by a U-shaped bracket. The pin
used to retain the clevis to the brake
pedal is usually called a clevis pin.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
The master cylinder is also separated
into two pressure-building chambers
(or circuits) to provide braking force
to one-half of the brake in the event
of a leak or damage to one circuit.
Figure 69–17
The composite master cylinder is made from
two different materials— aluminum for the
body and plastic materials for the reservoir
and reservoir cover. This type of reservoir
feeds both primary and secondary chambers,
and therefore uses a fluid level switch that
activates the red dash warning lamp if the
brake fluid level drops.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Both pressure-building sections of the master cylinder contain
two holes from the reservoir. The SAE term for the forward
(tapered) hole is the vent port, and the rearward straight drilled
hole is called the replenishing port.
Various vehicle and brake component manufacturers call these

ports by various names. The vent port is the high- pressure port.
This tapered forward hole is also called the compensating port.
The replenishing port is the low-pressure rearward, larger

diameter hole. The inlet port is also called the bypass port,
filler port, or breather port.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Figure 69–18 Note the various names for the vent port (front port) and the replenishing port
(rear port). Names vary by vehicle and brake component manufacturer. The names vent port
and replenishing port are the terms recommended by the Society of Automotive Engineers
(SAE).
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
At-Rest Position The primary sealing cups are between the
compensating port hole and the inlet port hole.
In this position, the brake fluid is free to expand and move from
the calipers, wheel cylinders, and brake lines up into the reservoir
through the vent port (compensation port) if the temperature rises
and the fluid expands.
If the fluid was trapped, the pressure of the brake fluid would
increase with temperature, causing the brakes to self-apply.
See Figure 69–19.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Figure 69–19 The vent ports must remain open to allow brake fluid to expand when heated by
the friction material and transferred to the caliper and/or wheel cylinder. As the brake fluid
increases in temperature, it expands. The heated brake fluid can expand and flow back into the
reservoir through the vent ports.
The pistons (primary

and secondary) are
retained by a clip at
the pushrod end and
held in position by
return springs.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Figure 69–20 As the brake pedal is depressed, the pushrod moves the primary piston forward,
closing off the vent port. As soon as the port is blocked, pressure builds in front of the primary
sealing cup which pushes on the secondary piston. The secondary piston also moves forward,
blocking the secondary vent port and building pressure in front of the sealing cup.
Applied Position
When the brake pedal
is pressed, pedal linkage
forces the push rod and
primary piston down
the bore of the master
cylinder.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
As the piston moves forward, the primary sealing cup covers and
blocks off the vent port (compensating port). Hydraulic pressure
builds in front of the primary seal as the pushrod moves forward.
The back of the piston is kept filled through the replenishing port.
Figure 69–21 The purpose of the replenishing port is to keep the volume behind the primary piston
filled with brake fluid from the reservoir as the piston moves forward during a brake application.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Released Position Releasing the brake pedal removes the
pressure on the pushrod and master cylinder pistons.
A spring on the brake pedal linkage returns the brake pedal to its
normal at-rest (up) position. The spring in front of the master
cylinder piston expands, pushing the pistons rearward.
At the same time, pressure is released from the entire braking

system and the released brake fluid pressure is exerted on the
master cylinder pistons, forcing them rearward.
As the piston is pushed back, the lips of the seal fold forward
allowing fluid to quickly move past the piston.
See Figure 69–22.

Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Figure 69–22 When the brake pedal is released, the master cylinder piston moves rearward.
Some of the brake fluid is pushed back up through the replenishing port, but most of the fluid
flows past the sealing cup. Therefore, when the driver pumps the brake pedal, the additional
fluid in front of the pressure-building sealing cup is available quickly.

2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
DUAL-SPLIT MASTER CYLINDERS
Dual split master cylinders use two separate pressure-building
sections. One section operates front brakes and the other section the
rear brakes on vehicles equipped with a front/rear-split system.
The nose end of the master

cylinder is the closed end
toward the front of the vehicle.
The open end is often called
the pushrod end of the master
cylinder.
See Figure 69–24.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Figure 69–24 The primary outlet is the outlet closest to the pushrod end of the master cylinder
and the second outlet is closest to the nose end of the master cylinder.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Some manufacturers operate the front brakes (which do the most
braking) from the “nose end” section (secondary piston end) of
the master cylinder.
The secondary piston has only one pressure-building seal. The

primary piston (pushrod end) requires two (2) seals to build
pressure. The nose end of the master cylinder is considered the
more reliable of the two pressure-building sections.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
NOTE: On vehicles equipped with front and rear split master cylinders,
the front brakes may or may not be operated from the front chamber. GM
typically uses the front (nose end) chamber for the front brakes and the rear
(pushrod end) for the rear brakes. Many other makes and models of
vehicles use the rear chamber for the front brakes. If in doubt, consult the
factory service manual for the exact vehicle being serviced.
If the rear section of the system fails, the primary piston will not
build pressure to operate the secondary piston. To permit the
operation of the secondary (nose end) piston in the event of a
hydraulic failure of the rear section, the primary piston extension
will mechanically contact and push on the secondary piston.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Figure 69–25
In the event of a primary system
failure, no hydraulic pressure is
available to push the second
piston forward. As a result,
the primary piston extension
contacts the secondary piston
and pushes on the secondary
piston mechanically rather
than hydraulically.
The loss of pressure in the

primary system is usually
noticed by the driver by a
lower-than-normal brake
pedal and the lighting
of the red brake
warning lamp.
The secondary piston,

will not be able to build
pressure due to the leak
in the system.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Always Check for Venting
(Compensation) - Part 1
Whenever diagnosing any braking problem, start at the master cylinder—
the heart of any braking system. Remove the reservoir cover and observe
the brake fluid for spurting while an assistant depresses the brake pedal.
Normal operation (movement of fluid observed in the reservoir) There
should be a squirt or movement of brake fluid out of the vent port of both
the primary and secondary chambers. This indicates the vent port is open
and that the sealing cup is capable of moving fluid upward through the port
before the cup seals off the port as it moves forward to pressurize the fluid.
If the vent port is blocked for any reason, the brakes of the vehicle may
self-apply when the brake fluid heats up during normal braking. Since the
vent port is blocked, the expanded hotter brake fluid has no place to
expand and instead increases the pressure in the brake lines. The increase
in pressure causes the brakes to apply. Loosening the bleeder valves and
releasing the built-up pressure is a check that the brakes are self-applying.
Then check the master cylinder to see if it is “venting.”
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Always Check for Venting
(Compensation) - Part 2
No movement of fluid observed in the reservoir in the primary piston
This indicates that brake fluid is not being moved as the brake pedal is
depressed. This can be caused by the following:
1. Incorrect brake pedal height—brake pedal or pushrod adjustment
could be allowing the primary piston to be too far forward, causing
the seal cup to be forward of the vent port. Adjust the brake pedal
height to a higher level and check for a too long pushrod length.
2. A defective or swollen rubber sealing cup on the primary piston
could cause the cup itself to block the vent port.

2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
DIAGONAL-SPLIT MASTER CYLINDERS
With front-wheel drive vehicles, the weight of the entire power train is on the front wheels and
80% to 90% of the braking force is achieved by the front brakes.
This means that only 10% to 20% of the braking force is being handled by the rear brakes. If the
front brakes fail, the rear brakes alone would not provide adequate braking force.
The solution is the use of a diagonal split master cylinder.
See Figures 69–26 and 69–27.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Figure 69–26 Front-wheel-drive vehicles use a diagonal split master cylinder. In this design one
section of the master cylinder operates the right front and the left rear brake and the other
section operates the left front and right rear. In the event of a failure in one section, at least one
front brake will still function.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Figure 69–27 Typical General Motors diagonal split master cylinder. Notice the two aluminum
proportioner valves. These valves limit and control brake fluid pressure to the rear brakes to
help eliminate rear wheel lockup during a rapid stop.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
In a diagonal split braking system, the left front brake and the
right rear brake are on one circuit, and the right front with the left
rear is another circuit of the master cylinder.
If one circuit fails, the remaining circuit can still stop the vehicle
in a reasonable fashion because each circuit has one front brake.
To prevent this one front brake from causing the vehicle to pull
toward one side during braking, the front suspension is designed
with negative scrub radius geometry.
This effectively eliminates any handling problem in the event of a

brake circuit failure.

2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
QUICK TAKE-UP MASTER CYLINDERS
Many newer vehicles use low drag disc brake calipers to increase
fuel economy. Due to the larger distance between the rotor and
the friction pads, excessive brake pedal travel would be required
before the pads touched the rotor.
The solution is a a quick take-up master cylinder, which

includes a larger diameter primary piston (low-pressure chamber)
and a quick take-up valve.
This type is also called dual-diameter bore, step-bore, or fast-

fill master cylinders.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
A spring-loaded check ball valve holds pressure on the brake fluid
in the large diameter rear chamber of the primary piston.
When the brakes are first applied, the movement of the rear larger
piston forces this larger volume of brake fluid forward past the
primary piston seal and into the primary high-pressure chamber.
This extra volume of brake fluid “takes up” the extra clearance of
the front disc brake calipers without increasing the brake pedal
travel distance.
See Figure 69–28.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Figure 69–28
Quick take-up master cylinder can be identified by the oversize primary low pressure chamber.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
At 70 to 100 psi, the check ball valve in the quick take-up valve
allows fluid to return to the brake fluid reservoir.
The quick take-up “works” until 100 psi is reached, and a metering
valve is not required to hold back fluid pressure to the front brakes.
Figure 69–29 The quick take-up valve
controls fluid flow to and from the
primary low pressure chamber.
See Figures 69–30 and 69–31.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Figure 69–30 As the brakes are applied, reduced low-pressure chamber volume results in a
pressure increase that causes fluid to bypass the primary cup seal.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Figure 69–31 The one-way sealing abilities of both a spring-loaded check ball and a cup seal
are used in the quick take-up valve.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
DIAGNOSING AND TROUBLESHOOTING
MASTER CYLINDERS
A thorough visual inspection is important when inspecting any master
cylinder. The visual inspection should include checking the following
items:
1. Check the brake fluid for proper level and condition.

(Brake fluid should not be rusty, thick, or contaminated.)
2. Check that the vent holes in the reservoir cover are open and
clean.
3. Check that the reservoir cover diaphragm is not torn or
enlarged.
4. Check for any external leaks at the lines or at the pushrod
area.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
The Brake Pedal Depressor Trick
The master cylinder can be used to block the flow of brake fluid. Whenever
any hydraulic brake component is removed, brake fluid tends to leak out
because the master cylinder is usually higher than most other hydraulic
components such as wheel cylinders and calipers
To prevent brake fluid loss that can easily empty the master cylinder
reservoir, depress the brake pedal slightly or prop a stick or other pedal
depressor to keep the pedal down. When the pedal is depressed, the
piston sealing cups move forward, blocking the reservoir from the rest of
the system. The master cylinder
stays full and the brake fluid stops
dripping out of brake lines that have
been disconnected.
Figure 69–32 A brake pedal depressor like this,

normally used during a wheel alignment, can
be used to block the flow of brake fluid from the
master cylinder during service work on the
hydraulic system.

2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
NOTE: If the cover diaphragm is enlarged, this is an indication that a
mineral oil, such as automatic transmission fluid or engine oil, has been
used in or near the brake system, because rubber that is brake fluid
resistant expands when exposed to mineral oil.
Figure 69–33 Some seepage is normal

when a trace of fluid appears on the
vacuum booster shell. Excessive leakage,
however, indicates a leaking secondary
(end) seal.

2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Figure 69–34 Pedal height is usually measured from the floor to the top of the brake pedal. Some
vehicle manufacturers recommend removing the carpet and measure from the asphalt matting on
the floor for an accurate measurement. Always follow the manufacturer’s recommended
procedures and measurements.
After a thorough visual

inspection, check for proper
operation of pedal height,
pedal free play, and pedal
reserve distance.
Proper brake pedal height is

important for operation of the
stop (brake) light switch.
See Figure 69–35.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Figure 69–35 Brake pedal free play is the distance between the brake pedal fully released and
the position of the brake pedal when braking resistance is felt.
Free play is the distance the

brake pedal travels before the
primary piston in the master
cylinder moves.
Most vehicles require brake

pedal free play between 1/8
and 1 1/2 in. (3 to 38 mm).
Too little or too much free

play can cause braking
problems that can be
mistakenly contributed to a
defective master cylinder.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Figure 69–36 Brake pedal reserve is usually specified as the measurement from the floor to the
top of the brake pedal with the brakes applied. A quick-and-easy test of pedal reserve is to try to
place your left toe underneath the brake pedal while the brake pedal is depressed with your
right foot. If your toe will not fit, then pedal reserve may not be sufficient.
Pedal reserve height

is easily checked by
depressing the brake
pedal with the right
foot and attempting
to slide your left foot
under the brake pedal.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Spongy Brake Pedal A spongy pedal with a larger than normal
travel indicates air in the lines. Check for leaks and bleed the air
from the system as discussed later in this chapter.
Lower Than Normal Brake Pedal A brake pedal that travels

downward more than normal and then gets firm is an indication
that one circuit of the dual-circuit hydraulic system is probably
not working.
Check for leaks in the system and repair as necessary. Another

possible reason is an out-of-adjustment drum brake allowing too
much pedal travel before the shoes touch the brake drum.
NOTE: A lower than normal brake pedal may also be an indication of air
in the hydraulic system.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Sinking Brake Pedal If the brake pedal sinks all the way to the
floor, suspect a defective master cylinder that is leaking internally.
This internal leakage is often called bypassing because the brake

fluid is leaking past the sealing cup.
NOTE: A sinking brake pedal, on a vehicle equipped with an antilock

braking system (ABS), could be caused by a defective dump valve.

2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
DISASSEMLY OF THE MASTER CYLINDER
Many master cylinders can be disassembled, cleaned, and restored
to service.
NOTE: Check the vehicle manufacturer’s recommendation before

attempting to overhaul or service a master cylinder. Many manufacturers
recommend replacing the master cylinder as an assembly.
Step #1 Remove the master cylinder from the vehicle, being

careful to avoid dripping or spilling brake fluid onto painted
surfaces of the vehicle.
Dispose of all old brake fluid and clean the outside of the master
cylinder.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Step #2 Remove the reservoir, if possible, as shown here.
Figure 69–37 Using a pry bar

to remove the reservoir from
the master cylinder.
(Courtesy of Allied Signal
Automotive Aftermarket)
Step #3 Remove the retaining bolt that holds the secondary piston
assembly in the bore.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Step #4 Depress the primary piston with a blunt tool such as a
Phillips screwdriver, a rounded wooden dowel, or an engine
pushrod. Use of a straight blade screwdriver or other nonrounded
tool can damage and distort the aluminum piston.
CAUTION: If holding the master cylinder in a vise, use the flange area.
Never clamp the body of the master cylinder.
Step #5 Remove the snap ring and slowly release the pressure on the
depressing tool. Spring pressure should push the primary piston out of
the cylinder bore.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Step #6 Remove the master cylinder from the vise and tap the
open end of the bore against the top of a workbench to force the
secondary piston out of the bore. If necessary, use compressed air
in the outlet to force the piston out.
CAUTION: Use extreme care when using compressed air. The piston
can be shot out of the master cylinder with a great force.
Figure 69–38 Whenever disassembling a

master cylinder, note the exact order of
parts as they are removed. Master cylinder
overhaul kits (when available) often
include entire piston assemblies rather
than the individual seals.

2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
INSPECTION AND REASSEMBLY OF THE
MASTER CYLINDER
Thoroughly clean the master cylinder and any other parts to be
reused (except rubber components) in clean denatured alcohol.
If the bore is OK, replacement piston assemblies can be installed

into the master cylinder after dipping them into clean brake fluid.
NOTE: While most master cylinder overhaul kits include the entire
piston assemblies, some kits just contain the sealing cups and/or O-rings.
Always follow the installation instructions that accompany the kit and
always use the installation tool that is included to prevent damage to the
replacement seals.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Step #1 Install the secondary (smaller) piston assembly into the bore,
spring end first.
Figure 69–39 Piston assembly.

(Courtesy of Allied Signal
Automotive Aftermarket)
NOTE: While most master cylinder overhaul kits include the entire
piston assemblies, some kits just contain the sealing cups and/or O-rings.
Always follow instructions that accompany the kit and always use the
installation tool included to prevent damage to the replacement seals.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Figure 69–40 To reinstall the reservoir onto a master cylinder, place the reservoir on a clean flat
surface and push the housing down onto the reservoir after coating the rubber seals with brake
fluid. (Courtesy of Allied Signal Automotive Aftermarket)
Step #2 Install the primary

piston assembly, spring end first.
Step #3 Depress the primary

piston and install the snap ring.
Step #4 Install the stop bolt.
Step #5 Reinstall the plastic
reservoir, if equipped, as shown
at left.
Step #6 Bench bleed the master
cylinder. This step is very
Continued important. See Figure 69–41.
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Figure 69–41 Bleeding a master cylinder before installing it on the vehicle. The master cylinder
is clamped into a bench vise while using the rounded end of a breaker bar to push on the
pushrod end with bleeder tubes down into the brake fluid. Master cylinders should be clamped
on the mounting flange as shown to prevent distorting the master cylinder bore.

2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
Check for Bypassing
If a master cylinder is leaking internally, brake fluid can be pumped from
the rear chamber into the front chamber of the master cylinder. This
internal leakage is called bypassing. When fluid bypasses, the front
chamber can overflow while emptying the rear chamber.
Whenever checking the level of brake fluid, do not think that a low rear
reservoir is always due to an external leak. Also, a master cylinder that is
bypassing (leaking internally) will usually cause a lower than normal brake
pedal.
NOTE: Brake fluid can drip from the outlet of the master cylinder and
could drip onto the vehicle. Brake fluid is very corrosive and can remove
paint. Use fender covers and avoid letting brake fluid touch any component
of the vehicle.

2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
INSTALLING THE MASTER CYLINDER
After the master cylinder has been bench bled, it can be installed
in the vehicle. Tighten the fasteners to factory specifications.
Figure 69–42
Installing a master cylinder.
Always tighten the retaining
fastener and brake lines to
factory specifications.
Bleed the system as

needed.

2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
SUMMARY
1. During a typical brake application, only about 1 teaspoon (5 ml or
cc) of brake fluid actually is moved from the master cylinder and
into the hydraulic system.
2. Pascal’s Law states that: “When a force is applied to a liquid

confined in a container or enclosure, the pressure is transmitted
equally and undiminished in every direction.”
3. Master cylinder reservoirs are large enough for the brakes to be

worn completely down and still have a small reserve.
4. The front port of the master cylinder is called the compensating

port and the rear port is called the inlet port.
Continued
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
SUMMARY (cont.)
5. Brake system diagnosis should always start with checking for
venting (compensation).
6. Dual split master cylinders that separate the front brakes from
the rear brakes are used on rear-wheel-drive vehicles.
7. Diagonal split master cylinders that separate right front and left
rear from the left front and right rear brakes are used on front-
wheel-drive vehicles.
8. Some master cylinders can be rebuilt, but the cylinder bore

should not be honed unless recommended by the manufacturer.

2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458
end

2009Pearson
PearsonEducation,
Education,Inc.
Inc.
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458

Chap 69

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Chap 69

Încărcat de

Drepturi de autor:

Formate disponibile

start

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition ©©2008

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition ©©2008

diagonal split master cylinder • dual split master cylinder

fast-fill master cylinder • filler port

hydraulic system • master cylinder

Pascal’s Law • pedal free play • pedal height • pedal

self-apply • step-bore master cylinder

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition ©©2008

No matter how much pressure or

This fact enables liquids in a

If the load on piston B is 50

See the formula on Page 826 of your textbook.

A practical example involves a master cylinder with a piston area of

Larger (area) pistons are used in wheel cylinders (calipers, if disc

Not only can hydraulics act as a “force machine” (by varying

On a typical vehicle, a driver-input force of 150 lb (660 Newtons)

The distance the shoes move is

Figure 69–6 Drum brake illustrating

Figure 69–7 The brake pad (friction material) is

The typical distance the pads

The result in this case is 100

Pascal states that pressurized liquid

It is piston surface area, not

In the simple brake system,

The relative movement of pistons

The results show that

If caliper piston area

With a dual- piston

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition ©©2008

Master Cylinder Reservoirs Most vehicles built since the early

Some countries have laws that require this type of reservoir.

See Figure 69–13.

Reservoir capacity is great enough

The typical capacity of the entire

Vehicles equipped with four-wheel

Master cylinders use a rubber diaphragm or floating disc to help

Whenever servicing a brake

Figure 69–14 All master cylinders should

Figure 69–15 Master cylinder with brake fluid level at the

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition ©©2008

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition ©©2008

To calculate the difference

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition ©©2008

Figure 69–16 The typical brake pedal is

Various vehicle and brake component manufacturers call these

The replenishing port is the low-pressure rearward, larger

See Figure 69–19.

The pistons (primary

At the same time, pressure is released from the entire braking

See Figure 69–22.

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition ©©2008

The nose end of the master

See Figure 69–24.

The secondary piston has only one pressure-building seal. The

The loss of pressure in the

The secondary piston,

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition ©©2008

The solution is the use of a diagonal split master cylinder.

See Figures 69–26 and 69–27.

This effectively eliminates any handling problem in the event of a

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition ©©2008

The solution is a a quick take-up master cylinder, which