overhaul brake system

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 2QUALIFICATION LEVEL

COMPETENCY-BASED LEARNING MATERIALS

No. Unit of Competency Module Title Code1. Service Starting System Repairing Starting System ALT7233072. Service Charging System Repairing Charging System ALT7233083. Service Engine Mechanical

SystemServicing Cooling System ALT723309a

Servicing Lubricating System ALT723309bServicing Gasoline Fuel System ALT723309cServicing Air Induction System ALT723309dServicing Diesel Fuel Injector ALT723309d

4. Service Clutch System Servicing and Repairing Clutch System

ALT723310

5. Service Differential and Front Axle Servicing Differential and Front Axle

ALT723311

6. Service Steering System Servicing Steering System ALT7233127. Overhaul Manual Transmission Pulling-out, Disassembling and

Checking Manual TransmissionALT723313a

Assembling and Testing Manual Transmission

ALT723313b

8. Service Brake System Identifying and Explaining Hydraulic Brake System

Operations and Functions

ALT723314a

Servicing Brakes ALT723314bOverhauling Brake

SystemsALT723314c

9. Service Suspension System Servicing Suspension System ALT723315aIdentifying and Explaining Suspension System Operating Principles, Components and Functions

(Conventional and Air Suspension)

ALT723315b

Servicing and Repairing Suspension System

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 self-check 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 component2. 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.

ALT723314CModule:

Overhauling Brake System

Date: Developed Date: Revised Page #Nov. 10, 2003 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


1. Hydraulic brake component is pull-out and disassembled as per prescribed procedure.

2. Component parts accurately marked and tagged.3. Parts properly rinse with specified cleaning solutions.4. Applied Personal safety procedure.5. Applied Vehicle and workshop safety procedure.6. Accurate tools for the job was used.

Resources :

1. Vehicle2. Well ventilated workshop3. Washing pan4. Clean rags5. Cleaning solution6. Air compressor/air gun7. Hydraulic jack8. Tire wrench9. Set of basic hand tools10. Goggles11. Wheel wedge12. Jack stands13. Apron14. Service manual15. Reference books16. CDs

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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

b. Brake Shoe Removal

c. Master Cylinder Removal

d. Wheel Cylinder Removal

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

Follow procedures in Job Sheet #1-1

Do Job Sheet #1-2

Do Job Sheet #1-3

Do Job Sheet #1-4

Read Information Sheet #1-5

Read Job Sheet #1.6 and follow the steps in cleaning components.



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JOB SHEET NO. LO1-1JOB 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. Raise and support the car in a secure manner.2. Remove the wheel3. Release the parking brake4. 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 petroleum-used 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.

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

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JOB SHEET No. LO1 - 2Job 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.

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JOB SHEET No. LO1-3JOB 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

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JOB SHEET No. LO1- 4JOB 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.

Fig 3 A wheel cylinder retaining ring can be removed using a pair of awls to pry the retainer tabs outward

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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.

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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.

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JOB SHEET No. LO1-5JOB 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.

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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.

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INFORMATION SHEET LO1-2APPLY 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 prevents normal breathing. There are many mists, gases, and fumes in a body shop that can damage the lungs and affect the ability to breathe.

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).

Fig. 1. If you do not wear proper protection when power sanding and grinding, harmful paint dust and dirt can get into your lungs. Always wear a NIOSH-

approved dust particle mask before grinding or sanding.

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

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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.

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SHOP SAFETY RULES

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.

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.

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.

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).

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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.

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Qualification : Automotive Service Technician NC III

Module Title : Overhauling Brake System

Learning Outcome #2 : Assemble and Mount Hydraulic Brake Component


1. Damaged and worn-out parts identified. 2. Reconditioned & replaced damaged parts.3. Assembled hydraulic brake components in accordance with standards.4. Mounted hydraulic components according to safety procedure and standard5. Performed bleeding with correct steps. 6. Checked ABS component conditions7. Performed bleeding with correct steps8. Road test was conducted as per vehicle operation’s manual9. Safety applied

Resources :

1. Vehicle2. Well ventilated workshop3. Washing pan4. Clean rags5. Cleaning solution6. Air compressor/air gun7. Hydraulic jack8. Tire wrench9. Set of basic hand tools10. Goggles11. Wheel wedge12. Jack stands13. Apron14. Service manual15. Reference books16. CDs

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Learning Outcome 2: Assemble and Mount Hydraulic Brake Component


1. Identifying damaged and worn-out parts.

a. Drum Inspectionb. Drum Measurementc. Brake Inspectiond. Rotor Inspectione. Rotor Measurement

2. Reconditioning and replacing damaged parts

a. Reconditioning a Caliperb. Rebuilding a Master Cylinder

3. Assembling hydraulic brake components in accordance with standards

a. Brake System Installationb. 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 Test as per vehicle operation’s manual

a. Road Test vehicle

9. Applying safety

a. See Shop Safety Procedures

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JOB SHEET NO. LO2-1MEASURE 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 dial3. 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

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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.

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

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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.

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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.

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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.

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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.

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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.

Fig. 2. An overheated rotor has small cracks or heat checks on the rotor surface

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JOB SHEET No. LO2-4JOB 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.

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JOB SHEET No. LO2-5JOB 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. Loosen the bleeder screw.2. 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 pistons3. 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. Slide the piston out of the bore.5. Removed the piston cups and spring.6. 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

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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.

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JOB SHEET NO. LO2-6JOB 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

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JOB SHEET NO. LO2-7TITLE 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

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JOB SHEET LO2-8JOB 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 direction2. 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.

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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.

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JOB SHEET NO LO2–9BLEEDING 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.

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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.

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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 all pertinent traffic laws.

Use 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.

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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.

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Qualification : Automotive Servicing NC II

Module Title : Overhauling Brake System

Learning Outcome #3 : Use Appropriate Tools and Equipment


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

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Learning Outcome 3: Use Appropriate Tools and Equipment


1. Using appropriate tools as per job requirements


2. Using appropriate Equipment as per job requirement


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PERFORMANCE TEST

Learner's Name Date

Competency: REPAIR SUSPENSION SYSTEM Test Attempt 1st 2nd 3rd

Directions: CALL INSTRUCTOR, ask instructor to assess your performance in the following critical task and performance criteria below

You will be rated based on the overall evaluation on the right side.

OVERALL EVALUATIONLevel

AchievedPERFORMANCE 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.

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 STANDARDSFor acceptable achievement, all items should receive a "Yes" or "N/A"

response.Yes No N/A

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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.

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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.

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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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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:..............................................................................................

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LO 2 : Check, assemble, and mount hydraulic brake component.


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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Code No.

ALT723314CModule:





LO 3 : Use appropriate tools and instrument.


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.

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Date:..............................................................................................

Code No.

ALT723314CModule:



ASSESSMENT INSTRUMENT

EVIDENCE PLANCompetency

standard: Automotive Service TechnicianIII

Unit of competency:

Service Brake System

Ways in which evidence will be collected: [tick the column]

Que

stio

n/In

terv

iew

Dem

ons

trat

ion

The evidence must show that the candidate …

1. Adjusted drum brake clearance at specified clearance.

2. Change hydraulic brake fluid without spillage and filled with specified level.

3. Performed bleeding the hydraulic brake system using the right steps and procedures.

4. Adjusted brake pedal as per specifications.5. 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.

ALT723314CModule:



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 No N/A

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. Conduct brake pedal free-play adjustment.5. Adjust emergency brake as per steps and specifications

6. Observe safety through-out the job is maintained

The candidate’s demonstration was:

Satisfactory Not Satisfactory

Code No.

ALT723314CModule:



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.

ALT723314CModule:



4. Identify these parts.

A. System A is a ________________________________ split system.B. System B is a ________________________________ split system

Code No.

ALT723314CModule:



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.

ALT723314CModule:



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.

ALT723314CModule:



ANSWER KEY

A. Identification: B. Name the parts of wheel cylindera. Primary cupsb. Cup c. Fluid level switch d. Primary pistone. Snap ringf. Return springg. Secondary cuph. Secondary pistoni. Bodyj. Return springk. Reservoir

a. Fluid inletb. Body c. Springd. Expandere. Pistonsf. Boot

C Identify the three parts of hydraulic system

a. Pressure differential valveb. Metering valvec. Proportioning valve

D. Multiple Choice

1. A2. B3. C4. A5. B6. B7. D8. C9. C10. D

Code No.

ALT723314CModule:



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.

ALT723314CModule:



ANSWER KEY

A. Identification

A. Cable guideB. C- washerC. Parking brake strutD. Wheel cylinder E. Return spring F. Parking brake springG. Hold down partsH. CupI. SpringJ. Pin K. Backing plateL. Adjuster springM. Adjuster screwN. Adjuster leverO. Adjusting cable

Code No.

ALT723314CModule:



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.

ALT723314CModule:



ANSWER KEY(DISK BRAKE)

IDENTIFICATION:

A. Outboard shoeB. Caliper bodyC. Inboard shoeD. BootE. Piston sealF. PistonG. BushingsH. Mounting boltI. SleeveJ. Caliper supportK. Shoe retainer springL. RotorM. Retaining tab

Code No.

ALT723314CModule:



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 23th 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. Jacinto2. Jeronimo L. de Jesus3. Dante V. Balagot4. Leopoldo P. Bueno

Academic Teachers: 1. Sonita Dr. Camacam2. Llarena T. Ocampo3. Elena C. Echija4. 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. Automotive Chassis Systems by: Birch, Thomas W.2. Automotive Mechanics 10 th Ed. by: Crouse and Anglin 3. Automotive Excellence 4. Hilton’s Truck & Van Repair Manual (93-97) 5. Oral Communication 6. Dictionary of Technical Terms

Code No.

ALT723314CModule:

