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OBJECTIVES:
After studying Chapter 67, the reader should
be able to:
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KEY TERMS:
adjustable pedals antilock braking system (ABS) apply
system
base brakes boost system brake balance control
system brake pedal brake warning lights
Department of Transportation (DOT) disc brakes drum
brakes
electric adjustable pedals (EAP)
Federal Motor Vehicle Safety Standards (FMVSS)
foundation brakes
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KEY TERMS:
gross vehicle weight rating (GVWR)
hydraulic system
lightly loaded vehicle weight (LLVW)
parking brake
red brake warning lamp
service brakes snub wheel brakes
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Continued
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Figure 671 Typical vehicle brake system showing all typical components.
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Mostvehiclesbuiltsincethelate1920suseabrakeoneachwheel.
Tostopawheel,thedriverexertsaforceonabrakepedal.Forceon
thebrakepedalpressurizesbrakefluidinamastercylinder.
Thishydraulicforce(liquidunderpressure)istransferredthrough
steellinesandflexiblebrakelinestoawheelcylinderorcaliperat
eachwheel.Hydraulicpressuretoeachwheelcylinderorcaliperis
usedtoforcefrictionmaterialsagainstthebrakedrumorrotor.
Theheavierthevehicleandthehigherthespeed,themoreheatthe
brakeshavetobeabletoabsorb.Long,steephillscancausethe
brakestooverheat,reducingthefrictionnecessarytoslowandstopa
vehicle.
SeeFigures672and673.
Continued
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Continued
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DRUM BRAKES
Drumbrakesareusedontherearofmanyrearwheeldrive,
frontwheeldrive,andfourwheeldrivevehicles.
Whendrumbrakesareapplied,brakeshoesaremovedoutward
againstarotatingbrakedrum.Thewheelstudsforthewheelsare
attachedtothedrum.Whenthedrumslowsandstops,thewheels
alsoslowandstop.
Drumbrakesareeconomicaltomanufacture,service,andrepair.
Partsarereadilyavailableandreasonablypriced.Onsome
vehicles,anadditionaldrumbrakeisusedasaparkingbrakeon
vehiclesequippedwithreardiscbrakes.
SeeFigures674and675.
Continued
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Continued
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Figure 675 Drum brake assembly as used on the right rear wheel.
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DISC BRAKES
Discbrakesareusedonthefrontofmostvehiclesbuiltsincethe
early1970sandontherearwheelsofmanyvehicles.
Adiscbrakeoperatesby
squeezingbrakepadson
bothsidesofarotoror
discthatisattachedto
thewheel.
Figure 676
Typical disc brake assembly.
Duetothefrictionbetween
theroadsurfaceandthe
tires,thevehiclestops.
Continued
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Allbrakingforcesmustprovideforthefollowing:
1. Equalforcesmustbeappliedtoboththeleftandrightsidesof
thevehicletoassurestraightstops.
2. Hydraulicsystemsmustbeproperlyengineeredandserviced
toprovideforchangesasvehicleweightshiftsforwardduring
braking.
Hydraulicvalvesmustbeincorporatedintothehydraulic
systemtopermitthemaximumpossiblebrakingforcesbut
stillpreventundesirablewheellockup.
Antilockbrakingsystems(ABS)arespecificallydesignedto
preventwheellockupunderalldrivingconditions,including
wetoricyroadconditions.
Continued
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3. Thehydraulicsystemmustuseafluidthatwillnotevaporate
orfreeze.Thefluidhastowithstandextremetemperatures
withoutboilingandmustnotdamagerubberormetalpartsof
thebrakingsystem.
4. Thefrictionmaterial(brakingliningorbrakepads)mustbe
designedtoprovideadequatefrictionbetweenthestationary
axlesandtherotatingdrumorrotor.Thefrictionmaterial
shouldbeenvironmentallysafe.Nonasbestosliningis
consideredtobesafefortheenvironmentandthetechnician.
5. Thedesignofthebrakingsystemshouldsecurethebrake
liningsolidlytopreventthemovementofthefrictionmaterial
duringbraking.
Continued
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6.
Mostbrakingsystemsincorporateapowerassistunitthat
reducesdrivereffortbutdoesnotreducestoppingdistance.
Vacuumfromtheintakemanifoldisthemostcommonlyused
sourceofvacuumforpowerbrakeboosters.Theengineitself
mustbefunctioningcorrectlyforproperoperationofthe
powervacuumbooster.
NOTE: Itisthismovementofthefrictionmaterialthatcausesbrake
noise(squeal).Variousmovementdampersareusedbythevehicle
manufacturerstohelpcontrolanymovementthatdoesoccur.Itis
importantthateverytechnicianrestoretheoperationofallaspectsofthe
brakingsystemwhenevertheyareserviced,eventhenoisedampers.
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Brakesystemcomponents
canbeclassifiedintosix
subsystemcategories,
dependingonfunction.
Figure 677
Typical brake system components.
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ApplySystemDriverstartsoperationofthesystembypressingthe
brakepedalorapplyingtheparkingbrake.Theapplysystem
includesalllevers,pedals,orlinkageneeded.
BoostSystemUsedonmostvehiclestoincreasebrakepedalforce.
HydraulicSystemBrakepedalforceistransferredtothehydraulic
system,whereforceisdirectedtothewheelbrakes.
WheelBrakesHydraulicpressuremovesapiston,inadiscor
drumbrakesystem,thatusesfrictiontopressmaterialagainsta
rotatingdrumorrotor.Resultingfrictionslowswheelrotation.
Continued
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BrakeBalanceControlSystemMechanical,electrical,and
hydrauliccomponentsensurebrakesareappliedquickly,with
balancedpressureforsafeoperation.Componentsinclude
meteringvalves,proportioningvalves,andantilockbraking
systemcomponents.
BrakeWarningLightsTheredbrakewarninglamplights
wheneverahydraulicsystemfailureoccurs.TheamberABS
warninglampordimredbrakelightindicatesanABSselftest
and/orapossibleproblemintheABSsystem.
SeeFigures679and6710.
Continued
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Figure 679 The red brake warning lamp alerts the driver to a possible brake system fault.
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Ifawheelstartstolockup,thepurposeoftheABSsystemisto
pulsethebrakesonandofftomaintaindirectionalstabilitywith
maximumbrakingforce.
ManyABSunitscausethebrakepedaltopulseiftheunitis
workingintheABSmode,acauseforconcernforsomedrivers.
ThepulsingbrakepedalinformsthedriverthattheABSisbeing
activated.
SomeABSunitsuseanisolatorvalveintheABSunittoprevent
brakepedalpulsationsduringABSoperation.Withthesetypesof
systems,itisoftendifficultforthedrivertoknowifandwhenthe
ABSunitisworkingtocontrolalockingwheel.
SeeFigure6711foranoverviewofatypicalABSonarear
wheeldrivevehicle.
Continued
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Figure 6711
Typical components of an antilock braking system (ABS) used on a rear-wheel drive vehicle.
Continued
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Fourpartsofthebrakesystemarespecificallyregulated:
Fluidreservoirandlabeling
Dashboardwarninglights
Amethodofautomaticadjustment
Amechanicallyengaging,frictiontypeparkingbrakesystem
ThemajorityofFMVSS135consistsofacomprehensivetest
proceduredesignedtorevealanyweaknessinavehiclesbraking
system.Thetestisusedbymanufacturerstocertifythebraking
performanceofallnewvehiclesavailableforpublicpurchase.
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FMVSS135BrakeTestThetestprocedureconsistsofupto24
steps,dependingonvehicleconfigurationandbrakingsystem.
Theactualperformancetestsaremadewiththevehicleloadedto
boththemanufacturersspecifiedgrossvehicleweightrating
(GVWR)andthelightlyloadedvehicleweight(LLVW),with
certainappliedbrakeforces.
Therearepreciseinstructionsforeverystepofthetest,including
thenumberoftimesthetestsmustberepeated,thesequenceof
thetesting,andtheallowablestoppingdistancefortheparticular
typeofvehicle.
Somehighlightsofthetestingprocedurefollow.
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AdhesionUtilization(torquewheelmethod)Forvehicles
notequippedwithABS,thistestisperformedatLLVWand
GVWRtodetermineifthebrakesystemwillmakeadequate
useoftheroadsurfaceinstoppingthevehicle.
ColdEffectivenessThistestisperformedatbothGVWRand
LLVW,todetermineifthevehiclewillhavesufficientstopping
powerwhenthebrakeliningmaterialsarenotpreheatedby
previousstops.
HighSpeedEffectivenessThistestisperformedonlyon
vehiclescapableofexceeding78mph(125km/h)todetermine
ifthebrakesystemwillprovideadequatestoppingpowerfor
allloadingconditions.Theallowablestoppingdistanceis
calculatedfromthemaximumspeedthevehiclecanattain.
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StopswiththeEngineOffThistestisforvehiclesequipped
withbrakepowerassistunits.Thevehicle,loadedtoGVWR,
muststopwithin230ft(70m),fromaspeedof62mph(100
km/h).Thistestmustberepeatedsixtimes.
AntilockFunctionalFailureThistestensuresthatservice
brakeswillfunctioncorrectlyintheeventofanantilock
functionalfailure,andthebrakesystemwarningindicatoris
activatedwhenanABSelectricalfunctionfailureoccurs.
VariableBrakeProportioningSystemThistestisperformed
onvehiclesequippedwitheitheramechanicaloranelectrical
variableproportioningsystem.Itensuresthat,intheeventofa
failure,thevehiclecanstillcometoastopinanacceptable
distance.Ifthevehicleusesanelectricallyoperatedvariable
brakeproportioningsystem,thebrakewarningsystemmust
immediatelyalertthedriverofanyelectricalfunctionalfailure.
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HydraulicCircuitFailureThistestisperformedtoensure
thatthedriverwillbealertedviathebrakewarningsystem
indicatorthatafailurehasoccurred,andthatthevehiclecan
stillbestoppedinanacceptabledistance.
BrakePowerAssistUnitInoperativeThistestmakessure
theservicebrakecanstopthevehicleinanacceptabledistance
withthebrakepowerassistunitinaninoperativestate.Itis
performedonvehicleswithbrakepowerassistunitsturnedoff
orinoperative.
ParkingBrakeTheparkingbrakealonewillholdthevehicle
stationaryineithertheforwardorreversedirectionona20%
gradeforaperiodofatleast5minutes.
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HeatingSnubsThisprocedureheatsthebrakesystemby
makingaseriesof15stopsfromahighspeed.Asnubisa
controlledbrakeapplication.ThevehicleisloadedtoGVWR,
withrapidaccelerationbetweeneachstoptominimizecooling
thebrakes.
HotPerformanceAfterthebrakesystemhasbeenheatedbya
seriesofheatingsnubs,thehotperformancetestis
immediatelyperformed.ThevehicleisloadedtoGVWRand
twostopsaremade.Thestoppingdistancemustbewithin
acceptablelimitsasspecifiedinthetest.Thistestensuresthat
thebrakesystemonthevehiclewillnotfadefollowingaseries
ofhighspeedstopsatGVWR.
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Althoughthesetestsmayseemextreme,rememberthattheyare
onlyaminimumstandardofperformance.
Anybrakerepairworkshouldalsoleavethebrakesystemcapable
ofmeetingFMVSS135.
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Regardlessofspecificlawsgoverningbrakerepair,atechis
alwaysliablefordamageorinjuriesresultingfromrepairs
performedinanunprofessionalorunworkmanlikemanner.
Thereisonlyoneacceptablegoalwhenmakingbrakesystem
repairs:torestorethesystemanditscomponentpartssothey
performtooriginalspecifications.
Thepurposeofanyrepairisto
restorelikenewperformance.
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SUMMARY
1. Drumbrakesareusedontherearofmostvehicles.
2. Discbrakesareusedonthefrontofmostvehicles.
Thesixbrakesubsystemsinclude:applysystem,boostsystem,
hydraulicsystem,wheelbrakes,brakebalancecontrolsystem
(whichincludesABS),andbrakewarninglights.
3. Anantilockbrakingsystem(ABS)pulsesthehydraulicforceto
thewheelstopreventthetiresfromlockingup.Alockedtire
haslowerfrictionthanarollingtire.
Continued
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SUMMARY
(cont.)
4. ThefederalbrakestandardscoveredinFMVSS135regulate
specificbrakeperformancerequirements,butnottheactual
designofthebrakingsystem.
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end
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