COMPETENCY BASED LEARNING
MATERIAL
Sector:
AUTOMOTIVE
Qualification:
Automotive Servicing NC II
Unit of Competency:
Service Brake System
Module Title:
OVERHAULING BRAKE SYSTEM
Technical Education and Skills Development Authority
East Service Road, South Superhighway, Taguig, Metro Manila
NATIONAL CERTIFICATE LEVEL 2
QUALIFICATION LEVEL
COMPETENCY-BASED LEARNING MATERIALS
No.
1.
2.
3.
Unit of Competency
Service Starting System
Service Charging System
Service Engine Mechanical
System
4.
Service Clutch System
5.
Service Differential and Front Axle
6.
7.
Service Steering System
Overhaul Manual Transmission
8.
Service Brake System
Module Title
Repairing Starting System
Repairing Charging System
Servicing Cooling System
Servicing Lubricating System
Servicing Gasoline Fuel System
Servicing Air Induction System
Servicing Diesel Fuel Injector
Servicing and Repairing Clutch
System
Servicing Differential and Front
Axle
Servicing Steering System
Pulling-out, Disassembling and
Checking Manual Transmission
Assembling and Testing Manual
Transmission
Identifying and Explaining
Hydraulic Brake System
Operations and Functions
Servicing Brakes
Overhauling Brake
Systems
9.
Service Suspension System
Servicing Suspension System
Identifying and Explaining
Suspension System Operating
Principles, Components and
Functions
(Conventional and Air
Suspension)
Servicing and Repairing
Suspension System
Code
ALT723307
ALT723308
ALT723309a
ALT723309b
ALT723309c
ALT723309d
ALT723309d
ALT723310
ALT723311
ALT723312
ALT723313a
ALT723313b
ALT723314a
ALT723314b
ALT723314c
ALT723315a
ALT723315b
ALT723315C
HOW TO USE THIS COMPETENCY BASED LEARNING MATERIAL
Welcome to the module in Overhauling Brake System. This module contains training
materials and activities for you to complete.
The unit of competency "Service Brake System" contains knowledge, skills and attitudes
required for Automotive Servicing. It is one of the specialized modules at National Certificate
level (NC II).
You are required to go through a series of learning activities in order to complete each
learning outcome of the module. In each learning outcome are Information Sheets and
Resources Sheets (Reference Materials for further reading to help you better understand the
required activities). Follow these activities on your own and answer the self-check at the end of
each learning outcome. You may remove a blank answer sheet at the end of each module (or
get one from your facilitator/trainer) to write your answers for each self-check. If you have
questions, don’t hesitate to ask your facilitator for assistance.
Recognition of Prior Learning (RPL)
You may already have some or most of the knowledge and skills covered in this learner's
guide because you have:
• been working for some time
• already completed training in this area.
If you can demonstrate to your trainer that you are competent in a particular skill or skills,
talk to him/her about having them formally recognized so you don't have to do the same training
again. If you have a qualification or Certificate of Competency from previous trainings, show it
to your trainer. If the skills you acquired are still current and relevant to the unit/s of competency
they may become part of the evidence you can present for RPL. If you are not sure about the
currency of your skills, discuss this with your trainer.
At the end of this module is a Learner’s Diary. Use this diary to record important dates, jobs
undertaken and other workplace events that will assist you in providing further details to your
trainer or assessor. A Record of Achievement is also provided for your trainer to complete
once you complete the module.
This module was prepared to help you achieve the required competency, in Servicing Brake
System. This will be the source of information for you to acquire knowledge and skills in this
particular trade independently and at your own pace, with minimum supervision or help from
your instructor.

Talk to your trainer and agree on how you will both organize the Training of this unit.
Read through the module carefully. It is divided into sections, which cover all the skills,
and knowledge you need to successfully complete this module.

Work through all the information and complete the activities in each section. Read
information sheets and complete the self-check. Suggested references are included to
supplement the materials provided in this module.

Most probably your trainer will also be your supervisor or manager. He/she is there to
support you and show you the correct way to do things.

Your trainer will tell you about the important things you need to consider when you are
completing activities and it is important that you listen and take notes.

You will be given plenty of opportunity to ask questions and practice on the job. Make
sure you practice your new skills during regular work shifts. This way you will improve
both your speed and memory and also your confidence.

Talk to more experience workmates and ask for their guidance.

Use the self-check questions at the end of each section to test your own progress.

When you are ready, ask your trainer to watch you perform the activities outlined in this
module.

As you work through the activities, ask for written feedback on your progress. Your
trainer keeps feedback/ pre-assessment reports for this reason. When you have
successfully completed each element, ask your trainer to mark on the reports that you
are ready for assessment.

When you have completed this module (or several modules), and feel confident that you
have had sufficient practice, your trainer will arrange an appointment with registered
assessor to assess you. The results of your assessment will be recorded in your
competency Achievement Record.
QUALIFICATION
:
AUTOMOTIVE SERVICING NC II
UNIT OF COMPETENCY :
Service Brake System
MODULE
Overhauling Brake System
:
Introduction :
This module contains the “know” and “do” units in Overhauling Brake System
It covers pulling-out & assembling hydraulic brake system, assembling and mounting
hydraulic brake component, and using appropriate tools and instruments.
This module consists of three (3) Learning Outcomes (LO’s), that contains learning
activities for both knowledge and skills supported with information sheet, job/operation sheet
and self-check. Before attempting to perform the manual exercises, see to it that you have
already read and understood the information/operating sheet and answer correctly the selfcheck provided in every Learning Activities.
Lastly, upon completion of this module, you have to undergo the assessment to be
administered by your instructor. A certificate of completion (COC) will be given to you as a proof
that you met the standard requirements for this module. The assessment could be made to
different methods, as prescribed in the competency standards.
Learning Outcomes :
At the end of this module you will able to:
1. Pull-out and disassemble hydraulic brake component
2. Check, assemble, and mount hydraulic brake component.
3. Use appropriate tools and instrument.
Assessment Criteria :
1. Hydraulic brake component is pulled-out and disassembled as per prescribed
procedure.
2. Component parts accurately marked and tagged.
3. Parts properly rinsed with specified cleaning solutions.
4. Personal safety procedure was applied.
5. Vehicle, and workshop safety procedure was applied.
6. Accurate tools for the job was used.
Pre-requisite :
Before you tackle this module you must complete first the module in Servicing Brakes.
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
1
QUALIFICATION
:
AUTOMOTIVE SERVICING NC II
UNIT OF COMPETENCY :
Service Brake System
MODULE
:
Overhauling Brake System
Learning Outcome #1
:
Pull-out and Disassemble Hydraulic Brake System
Assessment Criteria :
1.
2.
3.
4.
5.
6.
Hydraulic brake component is pull-out and disassembled as per prescribed
procedure.
Component parts accurately marked and tagged.
Parts properly rinse with specified cleaning solutions.
Applied Personal safety procedure.
Applied Vehicle and workshop safety procedure.
Accurate tools for the job was used.
Resources :
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Vehicle
Well ventilated workshop
Washing pan
Clean rags
Cleaning solution
Air compressor/air gun
Hydraulic jack
Tire wrench
Set of basic hand tools
Goggles
Wheel wedge
Jack stands
Apron
Service manual
Reference books
CDs
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
2
LEARNING EXPERIENCES
Learning Outcome 1: Pull out & Assemble Hydraulic Brake Component
LEARNING ACTIVITIES
SPECIAL INSTRUCTIONS
1. Pulling out and disassembling brake
component as per procedure
a. Drum Removal
•
Follow procedures in Job Sheet #1-1
b. Brake Shoe Removal
•
Do Job Sheet #1-2
c. Master Cylinder Removal
•
Do Job Sheet #1-3
d. Wheel Cylinder Removal
•
Do Job Sheet #1-4
•
Read Information Sheet #1-5
•
Read Job Sheet #1.6 and follow the
steps in cleaning components.
•
Read Information Sheet #1-7
•
Read Information Sheet #1-8
2. Marking and tagging parts accurately
a. Marking and tagging of parts
3. Rinsing parts properly with specified cleaning
solutions
a. Component Cleaning And Inspection
4. Applying personal safety
5. Applying vehicle & workshop safety procedure
a. Shop Safety Procedure
6. Using accurate tools for the job
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
3
JOB SHEET NO. LO1-1
JOB TITLE: Drum Removal
This typical brake job consists of the removal, service and inspection of a drum brake. The
parts should be inspected at least three times before disassembly, during cleanup and
reassembly to locate any faulty or damage components that may affect the final job.
PROCEDURES:
To remove a brake drum, you should use the following steps:
1.
2.
3.
4.
Raise and support the car in a secure manner.
Remove the wheel
Release the parking brake
Prevent the released of brake dust by
thoroughly wetting down the exterior of the
drum using a low-pressure brake washer.
Rotate the drum and try to get the solution
inside of the drum to wet the exterior. An
aerosol spray or vacuum enclosure can also
be used.
5. Determine the method of drum attachment and
remove the drum.
6. On non-drive axle drums, remove the dust cap,
wheel bearing cotter pin, and adjusting nut.
Then slide the drum and hub along with the
wheel bearings off the spindle (Figure 1).
Figure 1. The front drums on light trucks and
older RWD cars are normally retained by the
front wheel bearings. Rear drums on many
FWD cars are similar
a. If the drum is a floating drum, removed the
speed nuts and slide it off the axle flange
and log bolts.
b. If the drum is secured with bolts, remove
the bolts and slide it off the axle. If the drum
is stuck, check the drum for drum for two
holes threaded into the face. The bolts
used to retain the drum or any bolts of the
correct size can be threaded into these
holes and used as pullers to remove the
drum.
c. If a single nut on the axle secures the drum,
remove the nut and slide the drum off the
axle. If the drum is stuck, replace the nut so
it is free of the drum and even with the
end of the axle, then install a brake drum
puller .to remove the drum (Figure 2).
7. Thoroughly vacuum any dust or dirt from the
inside of the drum or washed in a petroleumused solvent, the friction surface must be
reconditioned or cleaned using denatured
alcohol or a commercial brake friction surface
cleaner to remove all trace of the solvent
residue.
Code No.
ALT723314C
Figure 2. If the rear drum is splined to the axle,
it is usually necessary to use a puller to
remove it. Many technicians prefer to loosen
the nut a few turns and leave it on the threads
to protect them while pulling the drum
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
4
JOB SHEET No. LO1 - 2
Job Title: Brake Shoe Removal
During shoe removal operations, many technicians position a pan of soapy water or
solvent under the bake assembly. When removing and replacing brake shoes, the
manufacturers recommended procedure for the particular car should be followed. To removed a
pair of brake shoes, you should:
1.
Carefully check the shoes to notes the
types of return and hold-down springs
and how they are connected to the shoes
and the backing plate.
2.
If you are not planning to service the
wheel cylinder, install a wheel cylinder
clamp to prevent the wheel cylinder
pistons from popping out of their bores
(Fig. 1).
Figure 1. A wheel cylinder clamp can be put on a
wheel cylinder to keep the pistons from coming out
when the shoes are removed
3.
Removed the return springs. Also removed any self-adjuster mechanism that has been
released. NOTE: On some duo servo brakes, the shape of the anchor causes the outer
return spring to the stretched a little further than the inner. It is a good practice to note
what spring is removed first so it can be installed last.
4.
Removed the hold –down springs and any self-adjuster mechanism that has been
released. NOTE: On brakes in which the shoe is pulled or slid off the anchor block to
release the return spring, the hold –down springs are normally removed first.
5.
If necessary, disconnect any remaining parking brake or self-adjuster linkage from the
shoes.
6.
If the wheel cylinder is to be serviced removed it.
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
5
JOB SHEET No. LO1-3
JOB TITLE: MASTER CYLINDER REMOVAL
Removal and replacement procedures for most power brake (vacuum or hydraulic booster)
units are very similar. Manual brake (without power assist) master cylinder often requires that
the pushrod be disconnected from the brake pedal.
To remove a master cylinder: (Fig. 1)
1. Take off the reservoir covers and
removed the fluid from the
reservoir.
2. Disconnect any wires connected to
the reservoir or master cylinder
cover.
3. Disconnect the brake tubes,
Depending on the system, there be
one, two or four tubes. Be sure to
use a tubing wrench for this
operation.
4. Removed the nuts or bolts attaching
the master cylinder to the power
booster or vehicle bulk head.
5. Slide the master cylinder off the
booster or bulkhead. If it will move
only as short distance but no
farther, replace one of the nuts or
bolts (finger tight) to support the
master cylinder and then disconnect
the pushrod from the brake pedal
after disconnecting the clip or pin
and clip holding the pushrod to the
pedal, repeat steps 4 & 5 (Fig. 2).
Fig. 1. After the tubing and electrical connections have
been disconnected, most master cylinders can be
removed by unscrewing the two attaching nuts and lifting
the master cylinder off the booster.
NOTE: With some power boosters, the pushrod will be free; test this by trying to pull it
outward. If it comes out, tape the pushrod to the front of the windshield keep it from getting
lost or forgotten.
Figure 2. It is usually necessary to disconnect the push rod from the brake pedal when
removing a non-power bake master cylinder
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
6
JOB SHEET No. LO1- 4
JOB TITLE: WHEEL CYLINDER REMOVAL
The following three methods are commonly used to attach a wheel cylinder to the backing
plate: nuts or bolts, a spring nut retainer, and a U-shaped locked plate with shims. Wheel
cylinder removal is normally done during a lining replacement. On single fault repair of a leaky
wheel cylinder, it is usually to remove and replace the contaminated lining.
To remove a wheel cylinder:
1. Removed the brake shoes
2. Disconnect the brake line from the wheel
cylinder (Fig. 1).
3. Disconnect the wheel cylinder mounting.
Fig. 1. After removing the brake shoes, a wheel
cylinder can be removed by unscrewing the
attaching bolts.
a. If bolts are used removed the bolts or nuts.
b. If a spring lock retainer is used, remove the retainer using a pair of awls or a special tool
(Fig 2-3).
Fig. 2. This special tool is used to expand the
retaining ring so it ca be removed or replaced.
Code No.
ALT723314C
Fig 3 A wheel cylinder retaining ring can be
removed using a pair of awls to pry the retainer
tabs outward
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
7
c. If a lock plate is used, tap out the
retainer plate using a screwdriver and
hammer (Fig. 4).
Fig. 4. This U-shaped retainer is slid out of its
groove using a punch or screwdriver and hammer.
HELPFUL HINT: When a service operation that requires the removal of the wheel cylinder,
caliper or line is done, the fluid drip from the open line can be stopped by partially applying
the brake. Prop the brake pedal to the point where the primary piston cup moves past the
compensating port; this will block the fluid from the reservoir.
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
8
INFORMATION SHEET LO1–1
Marking and tagging of Parts
The marking and tagging of parts is an activity of technicians that determine and guide of
service technician to assemble a certain unit or job.
1. Select appropriate marking and tagging
tools and instruments.
2. Review and analyze the assembly of
parts.
3. Identify the part where to put mark and
tag.
Fig. 1. Before removing a brake drum, place a chalk
mark next to the marked wheel stud. This index mark
helps you replace the drum in the same position
4. Be sure that the place mark or tag will
not be lost before disassembly.
5. Keep marking and tagging instruments
in good shape always.
Fig. 2. Placing a chalk mark at the end of the wheel
stud closest to the valve stem (circled) will help you
replace the wheel in the correct position.
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
9
JOB SHEET No. LO1-5
JOB TITLE: COMPONENT CLEANING AND INSPECTION
After shoe removal, the backing plate and any part that is going to be reused should be
cleaned and inspected. These parts should be washed in soapy water or solvent and air-dried.
On brake drums mounted on hubs with wheel bearings should also be cleaned and repacked.
Fig. 1. A combi-kit or hardware kit. This set includes new return and hold-down springs plus other small
parts that should be replaced along with the brake shoes.
1. Many technicians normally install new return springs and hold-down springs. Several
companies market a kit, often called a hardware set, that include these spring and other
parts that are often worn or damaged or for which replacement is advisable (Fig. 1). A shoe
returns spring is a critical part. If it is a weak or stretched, early shoe application or drag can
occur, which in turn can cause pull or rapid wear. No strength or length specifications for
return springs are available to the break technician, and their low cost does not warrant
spending much time to check them. Return springs are made in many different size and
shapes. Check the replacement spring against the old one to be sure that you have the
correct spring (Fig. 2). A popular but questionable method for testing a springs is to listen to
the sound as the spring dropped on the floor. A spring that makes a ringing noise is faulty
because the coils are stretched apart. Always replace the return spring in sets at both ends
of the axle. The spring at each end must be the same strength to reduce the possibility of
brake pull. Check any spring that is to be reused for severe discoloration, rusting or
stretched coils. Any damage or doubtful spring must be replaced.
Fig. 2. There are many shapes and
sizes of return springs.
Replacements should be carefully
checked against the old ones to
make sure they are correct.
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
10
2. On cars with self-adjusters, the adjusting lever should be checked for wear. With cable type
self-adjusters, be sure to check the lever for incorrect bends or cracks in the pivot area and
the cable for sign fraying and stretching (Fig. 3). Any damaged parts should be replaced.
Fig. 3. The various parts of a self-adjuster should be checked for wear.
3. When cleaning adjuster screws, they should be unthreaded allow through cleaning of all dirt
or rust from the threads and also to allow proper lubrication. Any adjusters with damaged
threads or teeth should be replaced.
4. When checking a backing plate, make sure that the platforms are clean and smooth and not
groove badly enough to catch a shoe. Small imperfections can be cleaned up with a fine file
or emery cloth.
5. If the shoe shows a lining wear pattern indicating a cocked shoe, the backing plate should
be checked to see if the platforms are worn or distorted. On brakes with an axle flange, the
relative height of the platforms can be easily checked by doing the following procedures:
a. Attach a dial indicator to the axle flange
b. Adjust the indicator stylus and dial to zero on one end of the platforms
c. Rotate the axle so the remaining platforms can be measured
At one time, a simple tool was positioned over the spindle to allow platform height checks.
When replacing a backing plate be sure to tighten the mounting bolts to the correct toque.
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
11
INFORMATION SHEET LO1-2
APPLY PERSONAL SAFETY
The most important action taken in any body shop is accident prevention. Carelessness
and the lack of safety habits cause accidents. Accidents have reaching effects, not only in the
victim, but also on the victim’s family and society in general. More importantly, accidents can
cause permanent disability or even death. Therefore all shop employees must foster and
develop a safety program to protect the health and welfare of those involved.
1. Shoptalk gives added information that will
help the technician to complete a particular
procedure or make a task easier.
2. Warning is given to prevent the technician
from making an error that could damage
the vehicle.
3. Caution, reminds the technicians to be
especially careful of those areas where
carelessness can cause personal injury.
4. Asphyxiation refers to anything that
Fig. 1. If you do not wear proper protection when
prevents normal breathing. There are
power
sanding and grinding, harmful paint dust and
many mists, gases, and fumes in a body
shop that can damage the lungs and affect dirt can get into your lungs. Always wear a NIOSHapproved dust particle mask before grinding or
the ability to breathe.
sanding.
5. Chemical burn results when a corrosive
chemical injures the skin or eyes. This can
result from various chemicals in a shop.
6. Electrocution, results when electricity
passes through you body. Sever injury or
death can result. A fire is a rapid oxidation
of a flammable material, producing high
temperatures. There are numerous
combustibles (paints, thinners, reducers,
gasoline, and dirty rags) in body shop. Any
can quickly cause a fire.
7. Explosions are air pressure waves that
result from extremely rapid burning. A
physical injury is a general category that
includes cuts, broken bones, strained
backs and similar injuries. To prevent
these painful injuries, constantly think and
evaluate every technique. Always think
about what you are doing and try to do it
better.
8. Respirators are needed in a paint shop to
keep airborne materials from being
inhaled. The must be used even when
adequate ventilation is provided (Figure 1
and figure 2).
Code No.
ALT723314C
Fig. 2. Cartridge type respiratory masks will filter
finer particles than fiber dust masks.
Fig. 3. This is a typical cartridge filter with a full
facepiece
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
12
9. Dust or particle respirator is basically a filter that fits over the nose and mouth to block small
airborne particles (Figure 3).
10. Air-supplied respirator consist of a half mask, full-face piece, hood or helmet and an air
supply hose. Clean, breathable air is supplied through the hose from a separate air source.
11. Eye and face protection is required at all times in most shops to comply with OSHA or
insurance company requirements. Eye protection should be worn when using grinders, disk
sanders, power drills, or pneumatic chisels and when removing shattered glass or working
with paints and other chemicals.
12. Ear protection defeats the noise of panel
beating, the piercing noise of sanding, the
radio blaring full blast it is impossible to
hear anything else (Figure 4) to protect ear
drums from damaging noise levels.
Fig. 4..(A) Ear muffs or (B) ear plugs should be
worn when grinding and doing other operations
producing loud noise.
13. Hand Protection it is wise to apply a good
skin cream (Figure 5).
Fig. 5. After working use a little silicone free
moisturizing cream to soften your skin.
14. Store paints materials property to prevent
fumes or a fire (Figure 6).
Fig. 6. All flammable materials must be stored in a
metal safety cabinet.
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
13
INFORMATION SHEET NO. LO1-3
SHOP SAFETY RULES
6.
Make sure your clothes are right for the
job. Dangling sleeves or ties can get
caught in machinery and cause serious
injury. Do not wear sandals or open-toe
shoes. Wear full leather shoes with
nonskid rubber heels and soles. Keep
long hair out of machinery by wearing a
cap.
7.
Do not wear any rings, bracelets, or
watches
when
working
moving
machinery or electrical equipment.
Jewelry can catch in moving machinery
with very serious results. Also a ring or
bracelet can accidentally create a short
circuit of the battery. Then the metal of
the ring or bracelet may become white
hot in an instant. This will severely burn
you.
8.
Wipe oil and grease off your hands and
tools. You need a good grip on tools and
parts.
9.
If you spill oil, grease, or any liquid on
the floor, clean it up. Help prevent injury
from slips and falls.
Figure 1.
Some people say, “accidents will happen!”
But safety experts disagree. They say
“Accidents are caused.” They are caused by
careless actions. They are caused by
inattention to the job. And they are caused by
using damaged or incorrect tools.” Fewer
accidents occur in shops that are neat and
clean.
To help prevent accidents, follow these safety
rules.
1. Work quietly and give your full attention to
the job you are doing.
2. Keep your tools and equipment under
control
3. Keep jack handles out of the way (Fig. 1).
Stand the creeper against the wall when not
in use.
4. Never indulge in horseplay or other foolish
action. You could cause someone to get
seriously hurt.
10. Never used compressed air to blow dirt
from your clothes. Never point a
compressed air blowgun at another
person.
11. Always wear eye protection when liquid
spray or particles are flying about. Safety
glasses, safety goggles or face shield
(Fig. 2) should always be available.
Always wear eye protection when using
grinding wheel (Fig. 3).
5. Never put screwdrivers or other sharp
objects in your pocket. You could cut or
stab yourself. Or you could damage the
upholstery in a car.
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
14
Figure 2. Always wear safety glasses, safety
goggles, or a face shield when liquid spray or
particles are flying or falling around you.
Figure 3. Always wear eye protection when using
a grinding wheel.
12. Watch out for sparks from a grinding
wheel or a welding job. The sparks can
set hair or clothes on fire
13. When using solvents or other chemicals,
wear goggles to protect your eyes. If you
get a chemical in your eyes, flush hem
with water at once (Fig. 4) then go to the
school nurse.
14. Always use the right tool for the job.
Figure 4. If solvent or some other chemical
splashes in your eyes, immediately wash them out
with water.
15. Keep your hands away from the engine fan and accessory drive belts when the engine is
running. Your hand could get caught in the fan r between a belt and a pulley. You could be
badly cut or even lose a fingers.
16. Do not stand directly in line with the engine fan when it is turning or the engine is running.
Some fans, especially fans with flexible blades, have thrown off a blade while spinning. A
flying fan blade may injure or kill anyone it strikes.
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
15
Qualification
:
Automotive Service Technician NC III
Module Title
:
Overhauling Brake System
Learning Outcome #2
:
Assemble and Mount Hydraulic Brake Component
Assessment Criteria :
1.
2.
3.
4.
5.
6.
7.
8.
9.
Damaged and worn-out parts identified.
Reconditioned & replaced damaged parts.
Assembled hydraulic brake components in accordance with standards.
Mounted hydraulic components according to safety procedure and standard
Performed bleeding with correct steps.
Checked ABS component conditions
Performed bleeding with correct steps
Road test was conducted as per vehicle operation’s manual
Safety applied
Resources :
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Vehicle
Well ventilated workshop
Washing pan
Clean rags
Cleaning solution
Air compressor/air gun
Hydraulic jack
Tire wrench
Set of basic hand tools
Goggles
Wheel wedge
Jack stands
Apron
Service manual
Reference books
CDs
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
16
LEARNING EXPERIENCES
Learning Outcome 2: Assemble and Mount Hydraulic Brake Component
LEARNING ACTIVITIES
SPECIAL INSTRUCTIONS
1. Identifying damaged and worn-out parts.
a.
b.
c.
d.
e.
Drum Inspection
Drum Measurement
Brake Inspection
Rotor Inspection
Rotor Measurement
2. Reconditioning and replacing damaged parts
a. Reconditioning a Caliper
b. Rebuilding a Master Cylinder
3. Assembling hydraulic brake components in
accordance with standards
a. Brake System Installation
b. Rotor Replacement
4. Mounting hydraulic components according to
safety procedures and standards
a. XXX
5. Performing bleeding with correct steps
a. See Bleeding of ABS
6. Checking ABS component conditions
a. XXX
7. Performing bleeding with correct steps
a. Bleeding ABS
8. Conducting Road
operation’s manual
Test
as
per
vehicle
a. Road Test vehicle
9. Applying safety
a. See Shop Safety Procedures
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
17
JOB SHEET NO. LO2-1
MEASURE DRUM DIAMETER
1. Adjust the drum micrometer, to the original diameter of the drum (Figure1).
Figure 1. A brake drum micrometer, or mike, must be set to the drum diameter by moving he anvil and
dial assemblies to the proper location on the graduated shaft.
NOTE: A drum mike can be checked against a standard as a large outside micrometer drum
mikes should be recalibrated (Figure 2).
Figure 2 Checking gauges or large outside
micrometers can be used to determine the
accuracy of a drum mike. The checking standard
shown has an inside width of exactly 11”. If the
readings differs, the mike should be calibrated by
adjusting the set screw
2. Place the mike in the drum so the
measuring end next to the dials enters first
and the rigid end enters last.
Figure 3. After the mike has been placed into the
drum, the anvil end is held tightly against the drum
while the dial end is moved to the highest reading
on the dial
3. Hold the rigid end of the mike firmly against
the drums inner surface and swing the
measuring end in an arc as you watch the
scale reading (Fig. 3). Position the mike at
the point of highest reading on the dial.
This is the amount of drum oversize. When
added to the size setting of the mike, it is
the actual drum diameter. For example, if
the mike is set to 10 in. and the dial reads
0.020, the drum diameter is 10.020 in.
(Figure 4).
Figure 4. A drum mike is read by adding the dial
reading to the graduated shaft setting (A) the size
is 11.390” (11.0 + 0.375 [3/8] + 0.015). In (B) the
size is 27.23 cm, or 272.3 mm (27.00 + 0.23) If the
mike was set to the actual drum diameter, the
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
18
reading on the dial would be the amount of drum
oversize
4. Lift the mike out of the out of the drum so
the right hand comes out first. The mike
can be damaged if the measuring end
leaves first and snaps out.
5. Re-measure the drum in two or three
locations and compare the measurements.
A Difference in reading indicates out of
roundness. Brake drum can also be
checked for radial run-out, which can
cause a pulsating brake pedal and possible
brake grab. Remount the drum into the hub
backwards and position a dial indicator on
the drums inner surface (Figure 5). Then
rotate the drum while watching the dial
indicator. More than 0.006 in. (0.15mm) of
run out can cause a problem. This check
can be affected by hub run out. If the
amount of run out is excessive, re-index
the drum on the hub and repeat your
check; if it is still excessive, the drum
should be turned or replaced.
Code No.
ALT723314C
Figure 5. Mounting the drum onto the hub
backwards allows a dial indicator to be used to
measure a drum for runout or out-of-round. More
than 0.011” (0.28 mm) of runout can cause
problems
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
19
JOB SHEET LO2-2
JOB TITLE: Brake Inspection
A brake inspection is performed to determine the condition of the brake system. The
inspection can determine the cause of complaint or service as preventive maintenance to
determine when if service is necessary.
To perform a brake inspection you should:
1. Depress and release the brake pedal several times.
2. Depress the pedal heavily. There should be no sponginess and the pedal should stop with
at least one-half of the available pedal travel left in reserve.
3. Depress the pedal moderately, about 25-35 lb. For about 15 seconds, making sure it does
not sink to the floor.
4. Depress and release the pedal several times under varying amounts of pressure as you
watch the warning light on he dash.
5. Check the brake warning light operation by cranking the engine. The light should come on
as the engine is cranking. On cars equipped with ABS and/or airbags, this warning light
should come on during cranking and remain on for a few seconds after the engine starts.
6. Apply the parking brake. The lever should not travel more than two-thirds of the available
distance and should provide enough braking power to hold the car in place.
7. On cars equipped with power brakes, with the engine off, depress the pedal several times to
exhaust the booster reserve. Hold the pedal down with a light pressure and start the
engine, the pedal should drop slightly but noticeably. With hydraulic boosters, the pedal
should drop and then rise back up. After running the engine several moments more, shut
the engine off, wait 90 seconds and depress the pedal lightly. One or more assisted brake
applications should occur.
8. Check the master cylinder for external leaks at the line fittings, mounting end. or reservoir
cover.
9. Remove the reservoir cover, not the condition of the diaphragm, and make sure the vent
hole on the cover is open.
10. Check the fluid level.
11. Run a clean finger around the bottom of the reservoir and checked for rust, dirt or other
contamination.
12. Watch the fluid in the reservoirs as the pedal is depressed
CAUTION: Do not lean directly over a master cylinder during brake application or
release. Fluid can spurt or spray high enough get on your face or you eyes. It is a
good practice to cover the reservoir wt clear plastic wrap to contain the fluid so you
can observe the movement.
13. Inspect the vacuum hose and check valves, hydraulic lines, and electrical connections to
make certain they are in good condition.
14. Raise and securely support the car.
NOTE: The rear axles of some FWD cars will bend if lifted by the center of the axle. These
axles should be lifted one at a time, with the place near the spring.
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
20
15. Rotate and shake or rock each of the wheels as you checks for excessive looseness and
free rotation of the wheel or axle bearings.
16. Removed at least one front and one rear wheel using the following procedure.
a. Remove any wheel covers (often locked)
b. Put an indexing mark on the end of the lug bolts that is closes to the valve stem.
c. Remove the lug nut using a six-point lug nut socket or lug wrench.
d. Remove the tire and wheel assembly.
17. Mark the drum next to the previously marked studs and remove the drum.
Safety tip: OSHA requirement state. “There should be no visible dust during brake
inspection and repair.” Removal of a brake drum can release dust and asbestos
fibers. The recommended method of preventing this is to flood the brake assembly
using a brake washer; rotate the drum as you thoroughly wet the inner components.
Aerosol sprays and vacuum enclosures can also be used.
NOTE: On brake drums that are mounted on the front of RWD cars or at the rear of
the FWD cars, the drum can often be removed at the wheel bearing as a wheel, hub,
and drum assembly. And follow the manufacturer recommendation on drum
removal if you are not sure of how to do it.
18. Check the brake lining for the amount and pattern of wear.
19. Check the brake springs for distortion, stretched, collapsed coils twisted or nicked shanks or
severe discoloration.
20. Checked the wheel cylinder for leakage.
21. Check the drum friction surface for cracks, unusual wear, worn or distorted surface.
22. Removed the caliper in the manner recommended y the manufacturer.
23. Inspect the lining for wear, noting the amount and pattern.
24. Check the caliper mounting hardware for wear or distortion.
25. Check the caliper piston booth for cracks or tears and leakage. No fluid seepage is
considered and acceptable.
26. Check the friction surfaces of the rotor for unusual wear.
27. Replace the caliper using the manufacturers recommended procedure. Being sure to tighten
the caliper mounting bolts or guide pins t the correct torque.
NOTE: When brake drag abnormally fast pad wear is the complaint, it is a good
practice to check for excessive brake drag.
28. If one or more problems were located, or there was a complaint of specific problem and the
cause has not been found, one or both of the other wheels need to be removed and the
brake assemblies inspected. If a preventative maintenance inspection is being made or the
cause of problem has been determined, replace the wheels. The following procedures
should be used:
a. Check the lug bolts and the wheel nut bosses for worn or elongated holes. Damaged
wheels should be replaced.
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
21
b. Snug down the lug nuts, making sure the tapered portion of the lug nut enters the
tapered opening of the wheel nut bosses.
c. Lower the car onto the ground and tighten the lug nuts to the correct torque using
tightening pattern that moves back and forth across brake drum or rotor can distorted by
over tightening the lug nuts or using the wrong order.
d. Replace the wheel cover or hub cap using a rubber hammer or the hammer portion of
the hub cap tool. NOTE: Uneven or excessive lug nut torque can cause braking
problems.
SAFETY TIPS: It is a good practice to retighten the lug nut after driving 10 to 20 miles
and it is a good idea to check lug nut tightness again after 100miles or 161 KM.
29. Check all visible lines for kinks or collapse sections that might cause fluid restriction or
leaks.
30. Check the parking brake cables equalizer and linkage.
31. Lower the car and operate the brake pedal through several slow, complete strokes until a
firm pedal is obtained.
32. Road test the car on streets with little or no traffic and make several stops from speeds of 20
to 25 mph (30-40km) at different pedal pressures. While the stop is occurring, check for pull,
grab, squeal or other unusual noises; excessive dive or pulsating pedal. Any faults indicate
a need for inspection to determine their cause.
33. Evaluate the findings of your inspection and make your recommendations on the inspection
report.
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
22
JOB SHEET No. LO2-3
JOB TITLE: ROTOR INSPECTION
The rotor should be inspected as part of the routine when doing a brake job and when
trying to determine the cause of particular complaint. Problems such as a pulsating pedal.
Pulsating or vibrating brake action and a grabby are often cause by a rotor that has an
excessive run-out or parallelism problem. Excessive runout can also knock the pads back and
cause a low brake pedal.
1. If the pads replaced, the rotor should be reconditioned or resurface. A rotor is recondition by
turning it in a rotor lathe.; this is also called truing or machining.
2. In case of used drums, the smooth varnish surface of the rotor is too much for good lining
break-in.
3. The ideal surface finish for breaking in organic linings is about 30 to 60 micro inches.
4. To install a new rotor, check the surface finishes and used that as a guide.
5. In deciding whether a particular rotor should be resurface, reconditioned, or replace a brake
technicians consider the following: the type of rotor (vented or solid), the amount of
scoring, the width of rotor, the amount of thickness variation (parallelism) the amount of
runout , how the rotor is mounted , the type of equipment available and the manufacturers
recommendations.
6.
Manufacturers recommends that the rotors be replace in pairs; if one needs replacement,
replace both. Also mixing rotor types is not recommended if a car with composite rotors
needs a replacement, replace that rotor with a composite type or replace both rotors with
cast type. A rotor cannot be turned if the machining process will make it too thin.
7. Some manufacturers do not recommend turning the rotors on certain vehicles; these rotors
should be replace if there is excessive scoring or thickness variation. Rubout problems can
be often be cured by reindexing the rotor on he hub.
8. Three reasons that justify turning a rotor: excessive rubout, excessive thickness rubout and
excessive grooving (0.006); even then, resurfacing can only be done if there will be
enough thickness after turning. The manufacturers state that if more than 0.015 in. has
worn from the rotor, it should be replaced.
9.
Begin with a visual inspection. Check
both the inner and outer friction surfaces
for scoring and wear. Normal wear
usually produces a smooth but wavy rotor
surface. Scores are abnormal wear
cause by a metal or abrasive object
digging into the rotor surface (figure 1).
Fig. 1. his rotor is ruined because the scoring is
too deep; machining cuts to true the surface will
produce a rotor that is too thin.
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
23
10. Also check visually for rotor glaze (a
highly glassy surface, which is somewhat
normal); blueing; contamination from
foreign materials such as oil, paint, or
silicon sprays; and heat checks. The
smooth and glassy surface should be
roughened by resurfacing the rotor to
ensure proper pad break-in. If the rotor
shows severe heat checking, it should be
turn or replaced (figure 2). A
contaminated rotor should be thoroughly
clean by using a friction surface cleaner
or by machining.
Code No.
ALT723314C
Fig. 2. An overheated rotor has small cracks or
heat checks on the rotor surface
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
24
JOB SHEET No. LO2-4
JOB TITLE: ROTOR MEASUREMENTS
It should be measured for size; specifically, the thickness of the friction surface is
measured with an outside micrometer or caliper, This measurement is normally taken midway
between the inner and outer edge of the friction surface. The minimum thickness of a rotor is
specified by the manufacturer, this dimension has been indicated on the rotor.
1. To check parallelism, the rotor is carefully measured at eight to twelve locations around the
rotor as the technician tries to find the thickness and thinnest rotor winds The
measurements are normally taken in the middle of the rotor surface. Subtracting the thin
measurement from the thick measurement from the tick measurement will give the amount
of thickness variation or parallelism. Compare these findings with the manufacturer
specifications.
2. Rotor rubout, often called lateral rubouts measured using a dial indicator. The dial indicator
is attached to the steering knuckle, spindle, caliper-mounting bracket, or caliper. Be sure
to mount the indicator so the indicator is at right (90 degrees) angle to he rotor surface,
3. It can also cause side to side motion of the caliper during a stop, and, if the caliper does not
slide easily; it can cause a pulsating, vibrating stopping action.
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
25
JOB SHEET No. LO2-5
JOB TITLE: TO REBUILD A WHEEL CYLINDER
Wheel cylinder rebuilding is the process of disassembling, cleaning, servicing and
checking the bore; and reassembling using new rubber parts. Some technicians believe that a
wheel cylinder is not worth rebuilding, especially if it has stuck or broken bleeder screw or a
stuck piston.
To rebuild a wheel cylinder:
1.
2.
Loosen the bleeder screw.
Removed the brake shoe links (Fig. 1.)
Fig. 1. An exploded view of a single-and a double
piston wheel cylinder. Note the position of the
rubber cups relative to the pistons
3.
If external boots are used, pull them off.
If internal boots are used, insert a
screwdriver through the center opening
in the boot to the edge of the boot and
the wheel cylinder and pry the boot
loose. Be careful not to damage the
cylinder bore (Fig. 2).
Fig. 2. This boot, which uses an internal retainer, is
removed by inserting a screwdriver under the edge
of the boot and twisting the screwdriver to pry it
upward
4.
5.
6.
Slide the piston out of the bore.
Removed the piston cups and spring.
Thoroughly clean the cylinder body, piston, spring, bleeder screw, and any other small
parts that are to be reused.
If the bore is acceptable and the other parts are in good condition the wheel cylinder can
be assembled in the following procedures:
1.
Wet the new cups and bore with assembly fluid or brake fluid and slide the cups and
spring to the cylinder bore. Be sure that you:
a. Position the cups so their lips are toward each other.
b. Do not let the lips of the cups catch on the edge of the cylinder.
c. Do not push the cups past the ports in the center of the bore; the lips of the cups might
be damaged because they tend to catch in the ports.
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
26
d. Do not push the cups inward in the cylinder so far that they cover the fluid inlet or
bleeder ports (Fig. 3).
Fig. 3. If the cups are not in the right positions, they will leak or the lips of the cups can be damaged
e. Fit the expander in position if required.
2.
Wet the piston with assembly fluid and
slide into position, making sure the flat
side of the piston is next to the flat side of
the cup (Fig. 4).
Fig. 4. As a wheel cylinder is assembled, the bore,
pistons, and cups should be lubricated with
assembly fluid or brake fluid.
3.
Replace the boots.
4.
Install the bleeder screw finger tight.
5.
Install the brake shoe links if required.
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
27
JOB SHEET NO. LO2-6
JOB TITLE: REBUILD A MASTER CYLINDER
1. Some reservoirs have a vacuum seal that can be pried from the master cylinder assembly.
2. Remove the reservoir cover and pour out any fluid that remains. Hold the unit over a
container and stroke the pistons a few times to pump any fluid out of the bore. Use a
rounded wooden dowel or metal rod for a push rod if necessary.
3. To remove the reservoirs in the unit with plastic reservoirs:
a. Clamp the master cylinder body in a vise by gripping a master cylinder mounting ear.
b. Remove any retaining pins or clips
c. Insert a large screwdriver or pry bar between the cylinder body and the reservoir and
pry the reservoir off the body.
a. Remove the rubber grommets from the cylinder body.
4. On some tandem units, you will need to locate and remove the secondary piston stop bolt or
pin. This bolt or pin enters the cylinder bore from the bottom of the reservoir or at the side or
bottom on the outside of the cylinder body. Many tandem master cylinders do not use this
stop bolt.
5. Clamp the cylinders body in a vise by gripping a mounting ears as described in step three
(3), push inward slightly on the primary piston, and remove the primary piston retaining ring.
Then remove the primary piston and spring.
HELPFUL HINT: some technicians push the primary piston inward, slide a iron wire or the
shank of a small drill bit through the primary bypass port, and let the primary piston slide
back slowly and catch on the wire. This keeps the spring pressure off the primary piston
while he retaining ring is being removed or reinstalled.
6. Slide the secondary piston out of the bore. If it is stuck, either grip it with needle-nose pliers
and pull it out, slam the cylinder body onto a block of wood, or use air pressure.
CAUTION: I air pressure is used, be careful that the piston does not fly out. It can be
contained by wrapping a shop cloth around the cylinder body, covering the bore end, and
holding the cloth securely while applying air pressure to the secondary outlet port.
7. Check the placement and direction of the seals and disassemble the secondary piston.
8. If the rebuilding kit is includes a replacement check valve and a tube seat, probe the outlet
ports with a small wire or a straightened paper clip to determine if residual valves are used
in the master cylinder.
a. Thread a #6-32 or a #8-32 self tapping machine screw through the outlet port. It should
thread in about ¼ in.
b. Using two screwdrivers placed, pry the screw upward to lift out the tube seat.
c. Remove the tube seat, check valve and spring.
NOTE: Never install a check valve in a master cylinder port if it did not originally have one.
9. Remove any other valve or switches as directed.
10. Using denatured alcohol or brake system cleaners, thoroughly clean the reservoir, cylinder
body and other parts that will be reused.
•
If the bore is acceptable and the other parts are in good condition, the master cylinder
can be assembled using the following procedure:
11. If a check valve has been removed, place the new spring, valve and seat in position and
lightly tap the new seat downward using a flat punch
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
28
JOB SHEET NO. LO2-7
TITLE OF JOB: BRAKE SHOE INSTALLATION
To install brake shoes on a backing plate, you should:
1. Check the shoes to determine the correct placement- primary or secondary, leading or
trailing and install the wheel cylinder if it has been removed.
2. If necessary, install the parking brake lever on the secondary or trailing shoe and connect
the parking brake cable t the lever.
3. Install the hold down spring and parts on the primary shoe. Make sure that the hold -down
pin is completely in place in the detents of the washer.
4. Install the hold-down spring and parts on the secondary shoe. As this is being done, attach
the self adjuster mechanism and parking brake strut, if necessary.
5. Install the return springs. The normal order of installation on a duo servo brae is to install the
primary shoe return spring first and then the secondary shoe return spring. If necessary
attach the self- adjuster as the return springs are being installed. The spring should be
hooked into the shoe and then installed on the anchor or second shoe.
NOTE: On cable-type self-adjusters, make sure the cable guide stays against the shoe
web and does not lift and allow the cable to go under the guide. And some technicians
recommend using pair of pliers to close the spring eye to the point where the spring end is
parallel to the shank. This prevents the spring eye from over opening up.
6. Inspect installation to be sure that everything is correctly installed. On most types of
Brakes, the shoes should be returned to the anchors, and then should be a slight
clearance at the parking brake strut. Test the self-adjuster to check its operation and then
removed the masking tape.
7. On cars that use adjuster screws, pre-adjust the shoe clearance. This can be done
Easily with a brake shoe gauge. First, adjust the gauge to fit inside the drum. Then adjust
the shoe to a slight gauge clearance. If a gauge is not available, expand the shoes until a
drag is felt when trying to slide the drum in place. Then remove the drum and turn the
adjuster inward about one-half turn to increase the clearance.
8. Install the drum.
NOTE: On drums with hub and wheel bearings, the wheel bearing should be cleaned,
repacked and adjusted.
Adjust the anchor to perform the major brake adjustment required by some manufacturers.
9. If the wheel cylinder has been rebuilt or replaced, bleed the air from the hydraulic brake
system.
10. Install the wheel and tighten the log bolts to the correct torque using the proper tightening
pattern. Note that over tightening the lug bolts can distort the brake drum.
11. Complete the brake shoe adjustment
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
29
JOB SHEET LO2-8
JOB TITLE: ROTOR REPLACEMENT
If a rotor is faulty, it must be replaced. On many cars this is simply a matter of lifting the
rotor of the hub and setting a new one in its place. As this done, always make sure there is no
dirt or grit between the rotor and hub, which can cause rubout. Rotor rubout should be checked
after mounting by securing the rotor with two or three properly tighten lug nuts and washers.
1.
Measure the amount of runout using a
dial indicator as describe in (figure 1).
Fig. 1. Occasionally, excessive rotor runout ca be
reduced to tolerable limits by reindexing the rotor.
A four-bolt rotor an be turned 180 or 190 degrees
in either direction
2.
If the runout is not within the
specifications, index it.
3.
Move the rotor of the one of the other
positions on the hub and recheck.
4.
The lug nut should be pressed out, one at
a time, using a specials fixture or hub
anvil so the rotor or hub flange is not
distorted (Figure 2).
Fig. 2. Some rotors are secured to the hub by the
wheel studs that are pressed in place. If replacing
a rotor, hub, or wheel stud, support the rotor
properly while pressing the studs out or back in.
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
30
5.
The new lugs should be locked in place
by using a center punch to upset the
metal of the metal of the shoulder of the
new lug bolts (Figure 3).
Fig. 3. A series of punch marks were made around
this new wheel stud to lock it in place
6.
Be sure to follow the manufacturer recommendations for rotor replacement and bearing
service.
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
31
JOB SHEET NO LO2–9
BLEEDING ABS
Figure 1. Some ABS units require special bleeding procedures. This modulator assembly is
equipped with a bleeder screw (A) line connections are bled by loosening the line fitting (B)
When service work on the hydraulic components is completed, a special bleeding process
for that particular system is usually required. This procedure is described in the manufacturer
service manual and in various technician service manuals from aftermarket component
manufacturers.
Some systems can be bled manually or by pressure. Some of these systems include a
bleeder screw at the hydraulic modulator or use a bleeding procedure such as loosening a line
fitting (Figure 1). Some systems use standard tools and procedures but require that the key be
off or on while purging air from certain locations. Some systems use flow from the electric
booster pump to bleed certain portions of the system. Other systems require the use of a
particular ABS tester to cycle solenoid valves for a thorough bleeding operation. These systems
can usually be bled using a more lengthy procedure without the special equipment.
Remember that in an ABS that uses an electric pump and accumulator, air can become
trapped in the accumulator. This air will not affect system operation until there is an ABS stop,
and then the air can be forced into the system, producing a low and spongy brake pedal.
When bleeding ABS, it is best to check the service manual for the correct procedure.
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
32
SELF CHECK NO. LO2-1
Your trainer will provide you with the necessary tools and equipment for the job, and
supervise you in your work; you will be graded based on the list below:
PERFORMANCE CRITERIA
YES
NO
1. Selected and used tools and testing instruments for the job
(appropriateness)
2. Observed correctly the procedures
3. Observed safety in performing the job.
4. Observed cleanliness/orderliness during and after the performance
5. Observed time element.
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
33
JOB SHEET NO. LO2-10
ROAD TEST
A technician uses a road test to confirm the nature of the problem and also to try to
determine the cause. Most technicians have a preferred test route that provides various bumps
and road surfaces and is away from heavy traffic. During a road test, the vehicle is driven in a
manner to try to simulate the particular problem. In other words, if you are checking for a noisy
shock, you want a rough road; if you are checking a pull condition or vibration problem, you
want a smooth road. Finding a good test route that is close to the shop can be difficult in many
metropolitan arrears.
While conducting a road test, you should observe the following guidelines:
 Make
sure the vehicle is safe to operate by quickly checking the tires, brake pedal
operation, and steering wheel feel.
 Observe
 Use
all pertinent traffic laws.
the vehicle’s seat and shoulder belt.
 Drive
the vehicle in a normal manner so you will not cause any additional wear or
damage.
 Note
the operation of the ABS and airbag warning lights if the vehicle is so equipped.
During the test, the technician will try to accomplish the following:

Confirm the customer’s complaint

Pin down the problem area, front or back and right or left side.

Determine the nature of the problem (ie noise, vibration, shake or pull)


Determine whether the problem is vehicle speed sensitive and what speed it is most
noticeable, whether it is torque sensitive, and whether it is engine speed sensitive or
gear ratio sensitive.
Determine whether it is a tire, suspension, steering alignment, or brake problem.
Note any unusual or unsafe condition to be brought to the attention of the owner.
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
34
SELF CHECK NO. LO2-2
Your trainer will provide you with the necessary tools and equipment for the job, and
supervise you in your work; you will be graded based on the list below:
PERFORMANCE CRITERIA
YES
NO
1. Performed pre-driving check-up.
2. Observed correctly the procedures in warming-up the engine
3. Observed traffic rules and regulations.
4. Observed cleanliness/orderliness during and after the performance
5. Pinned-down the problem.
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
35
Qualification
:
Automotive Servicing NC II
Module Title
:
Overhauling Brake System
Learning Outcome #3
:
Use Appropriate Tools and Equipment
Assessment Criteria :
1.
Appropriate tools as per job requirements
2.
Appropriate used of equipment & instrument as per job requirement
Resources :
1.
Well ventilated workshop
2.
Box wrench
3.
Open wrench
4.
Screwdriver
5.
Pliers
6.
Return spring puller
7.
Plastic hammer
8.
Multimeter
9.
Hydraulic jack
10. Tire wrench
11. Jack stands
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
36
LEARNING EXPERIENCES
Learning Outcome 3: Use Appropriate Tools and Equipment
LEARNING ACTIVITIES
SPECIAL INSTRUCTIONS
1. Using appropriate tools as per job
requirements
a.
See Shop Safety Procedures
2. Using appropriate Equipment as per job
requirement
a. See Shop Safety Procedures
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
37
PERFORMANCE TEST
Learner's Name
Date
Competency: REPAIR SUSPENSION SYSTEM
1st
Directions:
Test Attempt
2nd
3rd
OVERALL EVALUATION
CALL INSTRUCTOR, ask instructor to
assess your performance in the following
critical task and performance criteria
below
Level
Achieved
PERFORMANCE LEVELS
4 - Can perform this skill without supervision and with
initiative and adaptability to problem situations.
3 - Can perform this skill satisfactorily without
assistance or supervision.
You will be rated based on the overall
evaluation on the right side.
2 - Can perform this skill satisfactorily but requires some
assistance and/or supervision.
1 - Can perform parts of this skill satisfactorily, but
requires considerable assistance and/or supervision.
Instructor will initial level achieved.
PERFORMANCE STANDARDS
For acceptable achievement, all items should receive a "Yes" or "N/A"
response.
Code No.
ALT723314C
Module:
Overhauling Brake System
Yes
No
Date: Developed Date: Revised
Nov. 10, 2003
N/A
Page #
38
Terms and Definitions
1.
Adjustable Anchor- An anchor pin mounted on the backing plate so that it can be adjusted up or
down.
2.
Anchor Pin- The steel pin attached to a backing plate that is used to prevent the brake shoes
turning with the drum.
3.
Backing Plate- The mounting plate on which the component of drum brake are assembled.
4.
Bell Mounted drum- A brake drum that has been deformed so that the open end has a larger
diameter than the closed end.
5.
Bench Bleeding- A procedure used to removed all of the air from the hydraulic portion of a
component before mounting.
6.
Bleeder Screw- A small, hallow screw that is loosened to open it so air and fluid can go out of a
hydraulic component.
7.
Bleeding- A procedure that removes all of the air from the hydraulic system.
8.
Bonded Lining- A brake lining that is attach to a shoe using an oven-cured adhesive
9.
Bore- The diameter and walls of the cylinder.
10. Brake- A mechanism that converts energy to slow or stop a car.
11. Brake block- A short lining segment that is curved and drilled so it can be bolted or riveted onto a
shoe.
12. Brake Booster- A device that uses engine vacuum power steering pump pressure, or electricity to
reduce the amount of brake pedal pressure necessary to stop a car.
13. Brake fluid- A special fluid that used to transmit application pressure from the master cylinder to
the pistons in the wheel cylinders and calipers.
14. Brake Hose- A reinforced, flexible hose used to transfer hydraulic pressure from the rigidly
mounted steel lines to a caliper or axle that moves or rotate.
15. Brake light switch- A mechanically or hydraulically operated switch used to turn the stop lights on
when the brakes applied.
16. Brake line- A rigid steel tubes that conducts hydraulic pressure to the various parts of the brake
system.
17. Brake lining- A special friction material attached to the brake shoes and pads. It withstands high
temperature and pressures.
18. Brake pedal- The foot-operated lever against which the driver pushes to cause brake application.
19. Brake shoe- A curved metal part of the brake to which the lining is attached and that is push
against the inside of the drum to cause braking action.
20. Check valve- A valve that allows fluid or gas flow in only one direction
21. Compensating port- One or more passages in the master cylinder that are open between the
cylinder bore and the reservoir when the master cylinder is in the released position.
22. Denatured alcohol- Ethyl alcohol that contains methyl alcohol and is used to clean hydraulic parts.
23. Drum Brake- A brake design that generates stopping power from friction caused by shoes pushing
against the cylindrical portion of the drum.
24. Dual Master Cylinder- A master cylinder with two pistons and pressure chambers that is used with
split brake systems.
25. Duoservo- A brake drum design that generates servo action in both forward and reverse
directions.
26. Equalizer lever- A device used with parking brake cables to ensure equal pull on each cable.
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
39
27. HBS- Hydraulic brake system
28. Hydraulic pressure- The pressure within a hydraulic system measured in the amount of force on a
unit of area, commonly in pounds per square inch (psi).
29. Hydraulics- A system that uses fluid under pressure to transfer motion and pressure
30. Master Cylinder- The source of hydraulic pressure in a brake system. Operated by the brake pedal,
it supplies fluid pressure to the calipers and wheel cylinders.
31. Maximum Diameter- The largest size allowable for a brake drum or a cylinder bore.
32. OCCUPATIONAL SAFETY AND HEALTH SANITATION (OSHA) – A government body that
regulates working conditions as they relate to personal safety.
33. Primary cup- In a master cylinder, the cup that pumps fluid to the system.
34. Primary piston-In a tandem master cylinder, the piston that operated by the pushrod.
35. Primary shoe- the forward shoe; in a duoservo brake, the primary shoe is energized the rotation of
the drum and applies pressure on the secondary shoe.
36. Pushrod adjustment- an adjustment to ensure the proper length of the pushrod between the vacuum
booster and the master cylinder.
37. Reservoir- the portion of the master cylinder in which fluid is stored.
38. Residual pressure check valve- a hydraulic check valve used in some master cylinders to maintain
a slight pressure in the lines while the brake are released.
39. Return spring- the spring used to retain a brake shoe to released position. Also called pullback
spring or retracting spring.
40. Secondary cup- on a master cylinder piston, the cup that is used to prevent fluid from running out
the end of the bore or from running between the primary and secondary section.
41. Secondary piston- on a master cylinder piston, the piston that is applied by hydraulic pressure from
the primary piston.
42.
Secondary shoe- the rearwards in a duoservo brake; the energized primary shoe applies the
secondary shoe.
43. Self-adjusting- a drum brake mechanism that automatically adjusts the lining clearance when
necessary.
44. Servo brake- a drum brake design that uses the rotational force generated by one shoe to apply the
other one.
45. Tandem hydraulic system- a hydraulic brake system that is split between front and rear.
46. Tandem master cylinder- a master cylinder that is uses two pistons, one mounted behind the other.
47. Vacuum bleeding- a bleeding method that pulls fluid and air from the bleeder valve using vacuum.
48. Vacuum booster-a break booster that uses engine vacuum as a power source.
49. Wheel cylinder- a components in drum brakes that converts hydraulic pressure into a mechanical
force to push the shoes against the drum.
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
40
Learner’s diary
DIARY NOTES
Record important dates, jobs undertaken and other workplace events that will assist you in providing further
details to an Assessor.
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Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
41
Record of Achievement
Module: Overhauling Brake System
LO 1
: Pull-out and disassemble hydraulic brake component.
Performance Criteria:
1.1 Hydraulic brake component was pulled-out and disassembled as per prescribed procedure.
1.2 Component parts accurately marked and tagged.
1.3 Parts properly rinsed with specified cleaning solutions.
1.4 Applied personal-safety procedure.
1.5 Used accurate tools for the job.
Comments:
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Learner has satisfied the above performance criteria.
Learner’s signature:.......................................................................
Trainer’s signature:........................................................................
Date:..............................................................................................
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
42
Record of Achievement
Module: Overhauling Brake System
LO 2
: Check, assemble, and mount hydraulic brake component.
Performance Criteria:
2.1 Identified, reconditioned and replaced damaged or worn parts.
2.2 Assembled hydraulic brake component in accordance with the required steps procedure and standards.
2.3 Mounted hydraulic brake component according to procedure, safety, and standard.
2.4 Checked ABS component conditions as per manual instruction.
2.5 Performed bleeding in correct steps and procedure.
2.6 Conducted road test in accordance with vehicle operation manual.
2.7 Applied vehicle and workshop-area safety-requirement.
Comments:
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Learner has satisfied the above performance criteria.
Learner’s signature:.......................................................................
Trainer’s signature:........................................................................
Date:..............................................................................................
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
43
Record of Achievement
Module: Overhauling Brake System
LO 3
: Use appropriate tools and instrument.
Performance Criteria:
3.1 Used appropriate tools as per job requirement.
3.2 Used appropriate instrument/equipment as per job requirement.
3.3 Tools and equipment safety requirement was applied.
3.4 Observed personal safety-procedure.
Comments:
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Learner has satisfied the above performance criteria.
Learner’s signature:.......................................................................
Trainer’s signature:........................................................................
Date:..............................................................................................
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
44
ASSESSMENT INSTRUMENT
EVIDENCE PLAN
Competency
standard:
Automotive Service TechnicianIII
Ways in which evidence will be collected:
[tick the column]
Demonstration
Service Brake System
Question/Interview
Unit of
competency:
The evidence must show that the candidate …
1.
2.
4.
5.
Adjusted drum brake clearance at specified clearance.
Change hydraulic brake fluid without spillage and filled with
specified level.
3.
Performed bleeding the hydraulic brake system
using the right steps and procedures.
Adjusted brake pedal as per specifications.
Adjusted emergency brake as per specifications
6.
Observed Safety throughout the job.
NOTE: *Critical aspects of competency
Prepared
by:
Date:
Checked
by:
Date:
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
45
DEMONSTRATION
Candidate name:
Assessor name:
Unit of competency:
Service Brake System
Competency standards:
Automotive Service Technician III
Date of assessment:
Time of assessment:
Instructions for demonstration
Materials and equipment
OBSERVATION
 to show if evidence is
demonstrated
During the demonstration of skills, did the candidate:
Yes
1.
Adjust brake clearance at specified clearance.
2.
Change hydraulic brake fluid
3.
Perform bleeding the hydraulic brake system with correct
steps and procedures.
4.
5.
Conduct brake pedal free-play adjustment.
Adjust emergency brake as per steps and specifications
6.
No
N/A
Observe safety through-out the job is maintained
The candidate’s demonstration was:
Satisfactory
Code No.
ALT723314C
Not Satisfactory

Module:
Overhauling Brake System

Date: Developed Date: Revised
Nov. 10, 2003
Page #
46
WRITTEN TEST
DIRECTIONS: Read and interpret the following questions given.
1. Name the parts of this master cylinder.
A
B
C
D
E
F
G
H
I
K
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
2. Name the parts of the wheel cylinder.
A
B
C
D
E
F
G
------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
3. Identify the three parts of hydraulic parts of hydraulic system.
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
47
4. Identify these parts.
A. System A is a ________________________________ split system.
B. System B is a ________________________________ split system
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
48
II. Multiple Choice: Directions. Read and analyze the statement given. Write only the letter that
corresponds the best answer.
1. Which of this statement is correct?
A. A tandem, hydraulic brake system on a FWD car would provide poor braking if the front
brakes failed.
B. A diagonal split system is too expensive to be used on RWD cars.
a. a only
b. b only
c. both a and b
d. neither a nor b
2. Fluid will flow past the master cylinder primary cups.
a. as the brake pedal is released
b. just as the brake pedal starts application
c. during braking
d. never unless there is a failure
3. Fluid flows through the master cylinder bypass ports during the
a. start of brake application
b. entire brake application
c. start of brake release
d. completion of brake release
4. During construction of aluminum brake cylinders, a thin layer
called_______________________
a. anodizing
b. plating
c. bearingization
d. either a or c
5. The caliper piston material that maintains the coolest caliper fluid temperatures is
a. aluminum
b. phenolic
c. plated steel
d. polyacrylic
6. The square- cut O- ring seal in most calipers is not designed to
a. return the piston to a released position
b. stop corrosion from forming
c. seal the hydraulic pressure
d. remain pliable for the life of the brake shoes
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
49
7. Steel brake lines use___________________ to make pressure tight connections
a. double flares
b. ISO flares
c. Copper O- rings
d. Either a or b
8. Which of this statement is correct?
A. A metering valve is used to delay the application of disk brakes.
B. A proportioning valve is used to reduce the power of the rear brakes.
a. a only
b. b only
c. both a and b
d. neither a nor b
9. One of the features is not required for DOT – approved is that it must
a. be able to absorb and retain moisture.
b. Be free- flowing at all temperatures
c. Be expensive.
d. Have a high boiling point
10. Old brake fluid in a system can cause
a. corrosion of metals
b. fade caused by fluid boiling
c. expensive brake repairs
d. all of these
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
50
ANSWER KEY
A. Identification:
a. Primary cups
b. Cup
c. Fluid level switch
d. Primary piston
e. Snap ring
f. Return spring
g. Secondary cup
h. Secondary piston
i. Body
j. Return spring
k. Reservoir
B. Name the parts of wheel cylinder
a. Fluid inlet
b. Body
c. Spring
d. Expander
e. Pistons
f. Boot
C Identify the three parts of hydraulic system
a. Pressure differential valve
b. Metering valve
c. Proportioning valve
D. Multiple Choice
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
A
B
C
A
B
B
D
C
C
D
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
51
WRITTEN TEST
DRUM BRAKE
A. IDENTIFICATION: Identify the parts of this brake assembly.
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
_______________________________________
_______________________________________
_______________________________________
_______________________________________
_______________________________________
_______________________________________
_______________________________________
_______________________________________
_______________________________________
_______________________________________
_______________________________________
_______________________________________
_______________________________________
_______________________________________
_______________________________________
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
52
ANSWER KEY
A. Identification
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
L.
M.
N.
O.
Cable guide
C- washer
Parking brake strut
Wheel cylinder
Return spring
Parking brake spring
Hold down parts
Cup
Spring
Pin
Backing plate
Adjuster spring
Adjuster screw
Adjuster lever
Adjusting cable
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
53
WRITTEN TEST
DISK BRAKE
Identification:
A. Identify the disk brake parts.
A
B
C
D
E
F
G
H
I
J
K
L
M
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
__________________________________________
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
54
ANSWER KEY
(DISK BRAKE)
IDENTIFICATION:
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
L.
M.
Outboard shoe
Caliper body
Inboard shoe
Boot
Piston seal
Piston
Bushings
Mounting bolt
Sleeve
Caliper support
Shoe retainer spring
Rotor
Retaining tab
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
55
ACKNOWLEDGEMENT
Copyright TESDA
Centex: SOUTHERN ISABELA COLLEGE OF ARTS AND TRADES
First Published November 2003
This draft was prepared at the Competency-Based Learning Materials Development
Workshop conducted at the TESDA Women’s Center, from 23 th to 27th October 2003.
It was based on the competency standard for Automotive Service Technician developed
by the Skill Standard and Certification Office (SSCO), and the Competency-Based
Curriculum Instructional Modules developed by the National Institute for Technical
Vocational Education and Training (NITVET), Technical Education and Skills
Development Authority (TESDA).
Some materials for contextual learning (science, math and communication) were
supplied by Academic Teachers from different TESDA-supervised schools.
This learning instrument was developed by the following personnel:
Technology Instructors:
1. Exsuperio G. Jacinto
2. Jeronimo L. de Jesus
3. Dante V. Balagot
4. Leopoldo P. Bueno
Academic Teachers:
1. Sonita Dr. Camacam
2. Llarena T. Ocampo
3. Elena C. Echija
4. Jovita P. Pasamic
Vocational School Supervisor:
 Abraham B. Pascua
Facilitator:
 Cesar G. Ancheta
This work was produced with funding provided by TESDA.
REFERENCE AND FURTHER READINGS:
1.
2.
3.
4.
5.
6.
Automotive Chassis Systems by: Birch, Thomas W.
Automotive Mechanics 10th Ed. by: Crouse and Anglin
Automotive Excellence
Hilton’s Truck & Van Repair Manual (93-97)
Oral Communication
Dictionary of Technical Terms
Code No.
ALT723314C
Module:
Overhauling Brake System
Date: Developed Date: Revised
Nov. 10, 2003
Page #
56