LIBON COMMUNITY COLLEDGE

Libon, Albay

Course :BTVED AT III Course Title: AT 311 Brake System Technology

Instructor :Jeffrey S. Nicomedes Time Allotment: 12 hrs.
Semester :First (SY 2020-2021)
MODULE 2
Objective:
At the end of this module, you are expected to :
 Describe the construction and operation of the BRAKE SYSTEM FUNDAMENTALS.

Pre-test:
As part of your initial activity, try to assess your prior knowledge and experience related to Brake System
Fundamentals. Answer Task 1.

WHAT DO YOU ALREADY KNOW?

1. Automotive ____ provide a means of using friction.
2. The ______ is foot lever for operating the master cylinder and power booster.
a. Brake pedal assembly
b. Master cylinder
c. Brake booster
3. ______is a hydraulic piston pump that develops pressure from the hydraulic brake system.
a. Brake booster
b. Brake pedal assembly
c. Master cylinder
4. ______ is a vacuum electric or power steering operated device that assists brake pedal application.
a. Brake pedal assembly
b. Brake booster
c. Master cylinder
5. _______are metal tubing and rubber hose that transmit pressure to the wheel brake assemblies
a. Brake lines and hoses
b. Wheel brake and assemblies
c. Emergency brakes, or parking brakes
6. _______ are hydraulic-mechanical mechanisms that use hydraulic pressure to produce friction to slow
or stop each wheel.
a. Brake lines and hoses
a. Wheel brake and assemblies
b. Emergency brakes, or parking brakes
7. _______are mechanical or electric systems for applying rear brake assemblies.
a. Brake lines and hoses
b. Wheel brake and assemblies
a. Emergency brakes, or parking brakes
 WHAT DO YOU NEED TO KNOW?

MODULE 2: BRAKES OVERVIEW

Lesson 1: Brake System Fundamentals

Automotive brakes are designed to slow and stop a vehicle by transforming kinetic energy
(motion energy) into heat energy. Faster speeds, heavier vehicles, and quicker stops equal more heat.
A: Friction
Friction is the resistance to movement that results from two objects moving or rubbing against each
other. There are two types of friction: kinetic and static.

1. Kinetic friction occurs between two objects, one of which is moving.

Kinetic friction always produces heat. The more kinetic friction
produced, the more heat produced. Automotive braking systems use
kinetic friction to convert the energy of a moving vehicle into heat.
2. Static friction occurs between two objects that are stationary.
Automotive braking systems use static friction to hold a vehicle while it is parked. Static friction produces
no heat.

As a rule, the greater the pressure between two surfaces, the more friction they will produce.
Therefore, the greater the pressure applied to the brakes, the greater their stopping power will be.

On Drum Brake systems, Brake Shoes are applied to Brake Drums to create Friction while Disc
Brake systems apply Brake Pads to Rotors to create Friction.

One of the Friction surfaces used on Brake Systems is the Brake Lining which is mounted on either
a Brake Shoe or Brake Pad. Brake Linings produce Friction by directly contacting either a Brake Drum or
Disc (Rotor).

Brake Lining material must be somewhat softer than the Brake Drums or Discs to insure that the
Shoes and/or Pads wear rather than the Drums or Discs. Presently, most Brake Linings are made of
organic materials, metallic particles, and other minerals which are bonded or riveted to metal backing
plates.

Note: For years, asbestos was commonly used to make Brake Linings. However, since asbestos has now
been classified as a cancer-causing substance, federal law prohibits its use in Brake Systems.
When a Brake Lining is applied to a Drum or Disc, it is important that the proper amount of Friction is
produced in order to ensure that the Brakes are effective. Consider the following:

 If the amount of Friction is too great, the brakes may be “grabby” or overly sensitive. Overly
sensitive Brakes can cause a vehicle to skid.
 If the amount of Friction is too low, then Brake application will require excessive pressure. Applying
the Brakes using excessive pressure can create excessive Heat that could result in Brake Failure
 B: Tire Footprint
The point where a vehicle’s tire contacts the road is called the
Tire Footprint or Contact Patch. This ‘Footprint’ is the only place where
there is Braking Friction between the Tire and the Road. In general, the
larger a tire’s Footprint is, the greater its stopping ability will be.
Changes in the Friction of a Footprint due to tire size, tire condition, road
surface condition, or substances on the surface (water, ice, snow, dirt,
etc) will all affect a vehicle’s ability to stop.

Typically, the wider a tire is the larger its Footprint will be, and
the more stopping power it will have. However, it is important to
realize that the wider a tire is, the more Braking Power will be
needed to stop the vehicle.

C: Heat
As stated before, it is the Friction of converting Kinetic
Energy to Heat Energy that makes vehicles stop. The problem is;
what do we do with all of the Heat once it is created?
The reason we want reduced Heat in Brake Systems is that the
hotter the surface is between two objects, the less Stopping Friction will
be produced. Too much Heat in a Brake System will reduce the
amount of Friction produced, which will reduce the stopping ability of the
Brakes. This phenomenon is called Brake Fade.
Therefore, the Brake Lining material, and the surfaces that it
contacts, must have the following characteristics:
• Brake Drums or Discs must conduct Heat easily,
• Hold their shape under extremely high Heat,
• Withstand rapid temperature changes,
• Resist warping and distortion,
• Wear well in general
Because of those factors, Brake Drums and Discs are typically constructed of iron or steel combined
with aluminum.
Remember the following:

 If Brakes create more Heat than they can dissipate, braking effectiveness will be reduced.
 Excessive Heat can cause the bonding agents in a lining to melt and flow to the surface of a shoe
or pad. Those bonding agents can then produce a ‘glaze’ on the lining surface which will further
reduce the Brake’s effectiveness and cause Brake Fading. Brake application will then require more
pressure which will create more Heat and more glazing.
D: Weight and Speed
1. Vehicle Weight
The more Weight a moving vehicle has, the more Kinetic Energy it has. Recall that Brake
Systems convert Kinetic Energy into Heat Energy, so any increase in vehicle Weight puts a greater
demand on the Brakes.
How much does Weight affect a vehicle’s Braking? Consider that if a vehicle’s Weight doubles,
the amount of Kinetic Energy that the Brakes must convert to Heat Energy also doubles. That’s a lot of
Heat, and we already know what too much Heat can do to Braking effectiveness, don’t we?
Because of the effect of Weight on Braking, always be careful never to overload any vehicle,
especially a truck, where it is easier to do. Exceeding the Weight limit of any vehicle is actually
‘overloading’ the Brakes.
Note: Pulling a trailer essentially has the same effect on vehicle Braking as increasing the Weight of the
vehicle itself. The exception to this would be if the trailer has its own Brake System. This is just one
reason why you should always slow down when towing.
2. Vehicle Speed
Vehicle Speed also affects Braking, but to a much greater degree than Weight. How much more?
Consider that when the Speed of a vehicle doubles, the Brakes must convert, not double, but four times
the amount of Kinetic Energy into Heat Energy.
With this information it is easy to see how a combination of High Speed and excessive Weight
could easily push a vehicle’s Brake System beyond its performance limit, and result in a serious loss of
Stopping Power.

E: Service Brakes & Parking Brakes

Automotive Brake Systems fall into two major categories: Service Brakes (Hydraulically
Operated) and Parking Brakes (Cable or Electrically Operated).
Service Brakes are designed to stop a vehicle that is in
motion while a Parking Brake is intended to hold the vehicle while it
is parked.
Note: Always remember that a Parking Brake isn’t
designed to stop a moving vehicle and is not an Emergency
Brake!
Note: Parking Brakes often, but don’t always, use the same
Friction surfaces as the Service Brakes.

Master Cylinder and Brake Lines

F: Base Brake Components Brake Light

Base Brake components includes those parts that make up the
Hydraulic Brake System found on all vehicles. The term
“Base Brakes” will not include Antilock Brake or Traction
Control systems.
Self-Check No. 1
AUTOMOTIVE BRAKE SYSTEM
AUTOMOTIVE BRAKE SYSTEM
Answer keys: Pre-Test
1. to slow, stop, or hold the wheels of a vehicle.
2. A
3. C
4. B
5. A
6. B
7. C

Answer keys: Post-Test

1. C
2. D
3. E
4. B
5. A
AUTOMOTIVE BRAKE SYSTEM
LIBON COMMUNITY COLLEDGE
Libon, Albay

Course :BTVED AT III Course Title: AT 311 Brake System Technology

Instructor :Jeffrey S. Nicomedes Time Allotment: 12 hrs.
Semester :First (SY 2020-2021)
MODULE 2
Objective:
At the end of this module, you are expected to :
 Describe the construction and operation of diagnosing brake system.

Pre-test:
As part of your initial activity, try to assess your prior knowledge and experience related to Brake Diagnosis
Procedures. Answer Task 2.

WHAT DO YOU ALREADY KNOW?

1. A work order has the following components, except:
a. Customer authorization signature to allow repairs
b. Component or system defect responsible for the concern
c. Number of doors

2. The following are the few steps in Diagnosing Brake Problems except:
a.Description of customer concern
b.Listen to the Customer
c.Verify the Complaint

3. What is the corrective action when there is an excessive slack in the paking brake cables?
a. Repair or Replace as Necessary
b. Clean, lubricate, adjust, or replace as necessary
c. Compare to Service limit Specifications

4. What is the corrective action when the wheels cannot be rotated without excessive drag in
parking brake operation?
a. Repair or Replace as Necessary
b. Clean, lubricate, adjust, or replace as necessary
c. Compare to Service limit Specifications

5. What is the corrective action when there is thickness variation in brake rotors?
a. Replace
b. Clean, lubricate, adjust, or replace as necessary
c. Compare to Service limit Specifications
AUTOMOTIVE BRAKE SYSTEM

WHAT DO YOU NEED TO KNOW?

MODULE 2: BRAKES OVERVIEW

Lesson 2: Brake Diagnosis Procedures

Identify all service precautions, and review TSBs related to the vehicle’s braking system.
When completing the repair order, ask the owner for the vehicle’s service history.
A. Work Orders
The work order serves several functions.
•Itemizes the repairs by listing the cost of parts and labor
•Can be used to authorize the repair
•Has the necessary information on how to contact the owner and serves as documentation
for future reference
•May also specify limited warranties and liabilities of the shop
•May serve as a reference for recent service history for warranty or legal purposes
A work order typically has the following components.
•Customer name, address, and results of diagnosis, and any
phone number (home or work with important observations or remarks
extension number) •Component or system defect
•Date responsible for the concern
•Invoice number •Service performed to successfully
•Year, make, model, vehicle correct the concern
identification number (VIN), and •Labor procedures and costs based on
mileage of the vehicle the parts and labor estimation guides
•Name/initials of the service writer and •Outside labor procedures and costs
technician that include if a shop sent a particular
•Customer authorization signature to part out to another shop for repairs
allow repairs •Listing of each part that includes
•Description of customer concern name, description, and cost
•Vehicle service history information •Sales tax, which is usually calculated
on parts only
•Related technical service bulletins
(TSB) •Total that represents the final price
that the customer will pay for all
•Technician’s notes that includes charges related to the repair
diagnostic procedures performed, the

Work orders may be handwritten or prepared by entering codes in a computer terminal and then
printed.
Depending on the part, the following information may be required for ordering repair parts.
•Make, model, and model year (found on the driver’s side door jamb) of the vehicle
•VIN
•Engine information that includes engine size, in cubic inches or liters, the number of
cylinders, and the type of fuel system
•Wheelbase
•Number of doors
AUTOMOTIVE BRAKE SYSTEM
B. Brake Diagnosis

Diagnosing Brake Problems can be simplified by following a few basic steps:

• Listen to the Customer
• Verify the Complaint
• Perform a Visual Inspection
• Conduct a Brake Pedal Check
• Test Drive (before and after repairs)

It is very important to verify the Customer’s Concern before beginning diagnosis of a Brake
System. Have the customer describe the Brake System Concern while paying careful attention to
what they are describing. Ask the customer the following series of questions and record their
answers
.
• When did the concern first occur?
• Is the concern Continuous or Intermittent?
• Is the Brake or Antilock Brake System Warning Light ON or Flashing?
• What are the Driving Conditions when the concern occurs?
• What is the recent Service History of the vehicle?
• Is the vehicle making any unusual Noises?
• Does the vehicle pull during Braking?
• Based on the answers to the questions, determine the next step in the Diagnostic Process
for this vehicle.
AUTOMOTIVE BRAKE SYSTEM

•Parking brake operation - With the key on and the engine off, engage the parking brake.
The brake should apply with approximately half travel of the lever or pedal and the brake warning
light should turn on. Deactivate the parking brake and it should release immediately. The lever or
pedal should return to the release position and the warning light should turn off. Any problems with
the engagement or release of the parking brake could indicate a binding linkage.
•Brake warning light - With the key on and engine off (parking brake disengaged), if a brake
warning light comes on, with or without applying the service brakes, it could indicate a hydraulic
failure in the system.
CAUTION: Repair the hydraulic system before driving the vehicle.
AUTOMOTIVE BRAKE SYSTEM

D: Detailed Visual Inspection

Before starting Brake Work on any vehicle, a thorough Visual Inspection should be completed using
a Checklist similar to the one on the following page.

E: Visual Inspection Checklist

Component Inspect For: Corrective Action:

Brake Lines and Hoses Leaks Repair or Replace as
Crimps or Restrictions Necessary
Parking Brake Cables Excessive Slack
Clean, lubricate, adjust, or
Corrosion that could prevent replace as necessary
brake application or release
Parking Brake Operation Proper Operation

Wheels Rotate (parking

brake Clean, lubricate, adjust, or
engaged) replace as necessary
Wheels cannot be rotated
without excessive drag
(Parking Brake disengaged)
Brake Linings Excessive Wear Replace
Brake Hardware and Damage, wear, or corrosion
Hold- downs Replace
Missing Components
AUTOMOTIVE BRAKE SYSTEM

Brake Rotors Wear (reduced thickness)

Deep scoring or scratches Compare to Specifications
Thickness Variation Machine or replace as
Lateral Runout indicated
Excessive heat checking
Brake Drums Wear (excessive diameter)
Compare to Service limit
Deep scoring or scratches
Taper (bell mouth) Specifications
Out of round
Excessive heat checking

F: Test Drive
A road test is the only reliable way to check the stopping abilities of the brake system. Road
test all vehicles immediately after any brake work.

Procedure for preparing a vehicle for a road test

1. Make sure the brake pedal is more than 1.5 in from the floorboard. The brake pedal should feel
solid when depressed.
2. If the vehicle is equipped with power brakes, start the engine while depressing the brake pedal.
The pedal should move down slightly as the vacuum increases. Also make sure that other types
of power- boosting devices within the brake system are operating correctly.
3. Set the parking brake and try to move the vehicle. Make sure the parking brake can hold the
vehicle. Release the parking brake and note the vehicle’s freedom of movement. The vehicle
should move freely.
4. Let the vehicle begin to move very slowly and then apply the brakes. Make sure the brakes have
adequate stopping power before driving the vehicle further.

Procedure for road testing the vehicle

Note: Conduct road tests in areas where there is little or no traffic.
1. Accelerate to about 5 mph and gently apply the brake pedal.
2. Make sure the brakes work effectively and smoothly. The vehicle should not pull in either
AUTOMOTIVE BRAKE SYSTEM

direction during braking. There should be no unusual noise or brake pedal pulsation.
3. Accelerate to about 30 mph and apply the brakes firmly.
4. Make sure there is no wheel lockup, pulling, or unusual noise.

CAUTION: During a road test, never apply the brakes hard enough to lock up the wheels.

Road Test Flowchart

AUTOMOTIVE BRAKE SYSTEM

G: Removing Brake Dust

As a vehicle’s Brake Shoes and Pads wear, the lining material creates dust that must be
removed as part of performing a Brake Job. Due to federal regulations, it is no longer an
acceptable practice to just blow out the dust with an air hose..

1. The Dry Method of Dust Capture

•The Dry Method requires placing a metal and plastic enclosure over the Brake to be repaired.
This enclosure will contain built-in rubber gloves with which the Brake Parts can be handled
during cleaning.
•Using the built-in gloves, dust is blown from the Brakes with an air hose (within the enclosure)
where it will remain contained in the enclosure until a special vacuum cleaner removes it. The
Brake Dust can then be collected in a plastic bag for disposal.
2. The Wet Method of Dust Capture
•The Wet Method also requires placing a metal and plastic enclosure over the Brake. As in the
Dry Method, this enclosure contains built-in rubber gloves with which the Brake Parts can be
handled during cleaning.
•Using the built-in gloves, a specially designed Brake Parts Washer (see image at right) is used
to spray the Brake Parts within the enclosure. The Fluid washes the dust from the Brake Parts
and once again, a special vacuum cleaner collects the dust and fluid in a holding tank. The
Brake Dust can then be collected in a plastic bag for disposal.

CAUTION: Although Federal law has banned the use of asbestos in Brake Linings for many years,
it is still classified as a cancer-causing substance. If a technician ever finds himself working on a
vehicle with Asbestos-containing components, care must be taken to never breathe the Asbestos
or allow it to escape into the air.
CAUTION: Federal law also dictates precise procedures for disposing of captured Brake Dust.
Always follow the proper procedures.
CAUTION: Never use a household vacuum cleaner to remove Brake Dust from an enclosure. A
household vacuum cleaner cannot adequately filter the small particles.
CAUTION: If Brake Dust capture equipment is unavailable, or in poor working order, do not
perform Brake or Clutch work.

H: Vehicle Lifting

To perform most brake work, it is necessary to lift the

vehicle and work under the supported vehicle. When doing
brake work, observe all safety rules regarding lifting a vehicle.
CAUTION:
•When lifting a vehicle, always use proper lifting equipment and
observe all safety precautions.
•Never work under a vehicle that is supported by any type of
jack or by blocks. Always use solid metal support stands or a
lift that can support the entire vehicle by its frame.
•Never work under or around a vehicle supported by a bumper
jack. Bumper jacks are especially dangerous.
AUTOMOTIVE BRAKE SYSTEM

Self-Check No. 2
Directions: Answer the following as indicated. Use separate answer sheet in answering the
questions below.
A. Enumeration:
1. What are the steps on diagnosing brake problems?
______________________________________
______________________________________
______________________________________
______________________________________
______________________________________
2. What are the methods on removing brake dust?
______________________________________
______________________________________

B. Identify the following.

1. A ___________ is the only reliable way to check the stopping abilities of the brake system.
2. A _____________________ must be done before starting brake work on any vehicle.

C. Complete the Visual Inspection checklist below.

AUTOMOTIVE BRAKE SYSTEM
2. A
3. B
4. B
5. A
Answer keys: Post-Test
A.
1. Listen to the Customer
Verify the Complaint
Perform a Visual Inspection
Conduct a Brake Pedal Check
Test Drive (before and after repairs)

2. The Dry Method of Dust Capture

The Wet Method of Dust Capture
B.
1. road test
2. visual inspection
C.
1. Repair or Replace as Necessary
2. Parking Brake Cables
3. Wheels Rotate (parking brake engaged)
4. Excessive Wear
5. Brake Rotors
6. Compare to Specifications Machine or replace as indicated