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HANDBOOK
FOR
BRAKE
ADJUSTERS
May 2015
BUREAU OF AUTOMOTIVE REPAIR
BRAKE ADJUSTERS’ HANDBOOK
FOREWORD
This Handbook is intended to serve as a reference for Official Brake Adjusting Stations
and as study material for licensed brake adjusters and persons desiring to be licensed
as adjusters. See the applicable Candidate Handbook for further information. This
handbook includes a short history of the development of automotive braking equipment,
and the procedures for licensing of Official Brake Adjusting Stations and Official Brake
Adjusters.
No attempt has been made to relate the information contained herein to the specific
design of a particular manufacturer. Accordingly, each official brake station must
maintain as references the current service manuals and technical instructions
appropriate to the types and designs of brake systems serviced, inspected and repaired
by the brake station. Installation, repair and adjustment of motor vehicle brake
equipment shall be performed in accordance with applicable laws, regulations and the
current instructions and specifications of the manufacturer.
TABLE OF CONTENTS
DISCIPLINARY ACTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Suspension or Revocation of Licenses.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Voluntary Surrender of Licenses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Complaint Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Quality Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Complete Brake Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Mechanical Know How. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
HISTORY OF BRAKES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Definition of Braking Action. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PRINCIPLES OF OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Application of the Braking Principle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Friction in Braking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
The Foundation Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Stopping Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Shoe Energization Factor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Shoe Leverage Factor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Drum Deflection and Thermal Expansion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Lining Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Conclusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
HYDRAULIC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Application of Force. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Self Equalizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
MASTER CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Pressure Reducing Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SPLIT SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Checking the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Master Cylinder Brake Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Types of Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
ANTI-LOCK BRAKES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Anti-lock Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Note The Vehicle Tire Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Electronic Control Module.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Wheel Speed Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Modulator Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Anti-Lock Brake System Indicator Light. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
PARKING BRAKES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Integral Type.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Transmission Mounted or Drive Shaft Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Servicing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
The BAR Laws and Regulations Handbook is available from BAR, free of charge, on
the Internet at www.oal.ca.gov or at www.smogcheck.ca.gov.
For California Vehicle Code Sections 26301 through 26522 (relating to brake
requirements) see the California Vehicle Code (available at the Department of Motor
Vehicles). The Vehicle Code and regulation sections mentioned herein are also
published in the BAR Laws and Regulations Handbook. Vehicle Code and other
California laws are also available on the Internet at www.leginfo.ca.gov.
license will be canceled and a corrected regulations are also contained in the Laws
license for the balance of the unexpired and Regulations Handbook published by
term will be issued. BAR. Certain requirements are as follows:
License Term. Official Brake Adjusting a. Display of Station Sign. Each official
Station licenses are valid for one year and brake adjusting station must obtain and
may be renewed upon expiration. Stations display an official station sign meeting the
whose license has expired and has not specifications contained in Section 3309 of
been renewed shall immediately cease any Title 16, CCR prior to being inspected by a
activity requiring a license. BAR representative. The sign must be
displayed in a location where it is clearly
License Renewal. A renewal application is visible from outside the station, either on
normally mailed to the dealer prior to the the exterior of the premises or in a window.
expiration of the license. (If the dealer does Information regarding vendors of official
not receive a renewal application before station signs may be obtained from the
the station license expires, the dealer BAR Representative who inspects the
should call the Licensing Unit for further station, the Consumer Information Center,
instructions.) The dealer should send the (800-952-5210), or the BAR Internet site
renewal application plus a fee of $5 to the www.autorepair.ca.gov.
Licensing Unit during the 30-day period
prior to the date of expiration. If the license b. Presence of an Official Adjuster. A
is allowed to expire, the station may no licensed brake station must provide the
longer operate as a licensed station, but services of an appropriately licensed
the dealer may still apply for renewal of the adjuster during normal daytime business
license by sending an application plus a hours for not less than 40 hours per week,
late renewal fee of $7.50 during the 30-day or if open less than 80 hours per week, for
period following the expiration date. A not less than one-half of the total hours
license will not be renewed if the each week the station is open for business.
application is received by the Licensing An official station which no longer employs
Unit more than 30 days after the date of a licensed adjuster shall immediately
expiration. The dealer will have to apply for remove or cover the official station sign and
a new license and send $10, the fee for a cease to operate as a licensed station. If
new license, to the Licensing Unit. the station does not employ an official
adjuster within 60 days, the official station
General Requirements. license and all unused certificates of
adjustment shall be returned to BAR.
The specific and detailed requirements
applicable to official brake adjusting c. Posting of Price Sign. Each official
stations are contained in Article 2 starting station except a fleet owner station may
with Section 3304 and Article 4 starting with make reasonable charge for the work
Section 3320 of Title 16 of the California performed and shall post conspicuously a
Code of Regulations (CCR). These list of price ranges for the specific activities
for which it is licensed. Prices may be e. Adjustment and Repair. All adjusting
stated either as a fixed fee or an hourly rate and repairing of brakes and related systems
on a time-and-material basis. No added necessary to correct and clear violations
charge shall be imposed for the issuance of noted on an enforcement document and to
an Official Brake Adjustment Certificate or issue an official Certificate of Compliance -
certifications on enforcement documents of Brake Adjustment shall be performed in an
the correction of brake violations. No official station in accordance with accepted
charge relating to repair, replacement of industry practices, standards, and
parts, or adjustment of brakes shall be recommendations, the specifications and
imposed in addition to the posted price for instructions of the vehicle or brake
such adjustment or inspection unless such component manufacturer, and the
additional work and added charges are instructions and regulations of BAR. Official
authorized in advance by the vehicle owner stations are advised to maintain reputable
or operator. business and performance standards in all
transactions, including work not requiring
d. Brake Adjustment Certificates and official certification.
Cer t i f i c at i o n o f En f o r c em en t The adjuster shall inform the customer of
Documents. Official brake stations may any other defective conditions present or
obtain brake adjustment certificates at the likely to occur in the future which have
nearest BAR office or by mail. Mail come to the adjuster’s attention in
requests may be made by sending a conjunction with inspection of the vehicle
request for certificates with a check to: and correction of specified defects. The
Department of Consumer Affairs - BAR adjuster shall inform the customer of the
P.O. Box 989001, West Sacramento, CA amount of braking material remaining on
95798-9001. Certificates are sold only to the pads/shoes, as appropriate.
an authorized representative of a licensed
brake station and identification of such If the customer does not authorize
persons is required. additional repairs to correct other defects
found during the inspection, the adjuster
(1) A copy of each brake certificate shall certify that only the specific defects
issued shall be filed and retained by the listed on the enforcement form have been
station for three years from the date of corrected. BAR suggests that needed
issue. It is a good idea to write the repairs also be documented on the repair
certificate number on the repair order for order.
future reference. The class of both the
station's and installer's licenses shall be Certification by a licensed adjuster on an
included on the certificate of adjustment. enforcement form that a violation has been
corrected shall include date of correction,
(2) Brake certificates and repair orders/ station and adjuster license numbers, and
invoices shall be available for inspection the adjuster’s signature.
by a representative of the Bureau of
Automotive Repair. All records must be
maintained for a period of 3 years.
Lost, Destroyed, or Mutilated Adjuster (d) Commits any act involving dishonesty,
Licenses or Additional Copy Needed. fraud, or deceit whereby another is injured.
knowledge of complete brake systems - of internal brakes for both service and
from pedal to wheel - with an parking purposes.
understanding that all parts of the system
must work together when the brakes are Early internal type brakes were called
applied. A thorough understanding of "mechanical brakes." The brake shoes
modern brake systems, including manual were pedal-operated through a system of
systems, power assisted systems, rods or cables and cams. These
disc/drum systems, disc/disc systems and mechanical wheel brake assemblies each
anti-lock systems, is essential. consisted of three principal parts: (1) a
brake drum; (2) brake linings; and (3) brake
CHAPTER 3 - HISTORY OF BRAKES shoes.
AND PRINCIPLES OF OPERATION
Internal Emergency Brakes.
HISTORY OF BRAKES.
The internal expanding brake was first used
Definition of Braking Action. only as an emergency hand brake and was
operated by a simple hand brake lever.
When force is applied to retard or stop a
moving object, braking action is being Hydraulic Brakes.
applied. To stop a revolving wheel, an
opposing force is placed against it, thus Hydraulic brakes are operated by applying
causing a braking action. pressure to a foot operated master cylinder
which forces a special-type hydraulic fluid,
External Mechanical Brake. through tubing, to each of the wheel
cylinders. The hydraulic brake was first
The first automotive brake was an external used about 1921. Since that time,
type, so called because the brake lining hydraulic, air, vacuum, and electrically
was attached to a steel band which was operated systems have replaced
fitted around the outer surface of the drum. mechanical systems, with few exceptions,
Through mechanical means the brake band i.e., some older motorcycles, etc.
was clamped around the drum, thus
causing braking action. PRINCIPLES OF OPERATION.
Higher vehicle speeds require faster stops. Brakes reduce motion of the wheels of a
The fact that external brakes were subject moving vehicle by developing friction to
to weather and road conditions, and that convert the kinetic energy of the vehicle
normal drum expansion often caused into heat. This heat is dissipated into the
brakes to lock, brought about the adoption surrounding air as rapidly as possible.
Cooling also occurs during non-braking vehicle weight, tire size, and the desired "K"
intervals. factor. Excess brake torque capacity would
not improve performance and could make
Friction in Braking. braking unduly sensitive, reducing control
during normal easy stops or on slippery
Several applications of friction occur in the surfaces.
braking process:
The Foundation Brake.
a. Rolling Friction. The only contact
between the vehicle tires and the road is a The brake shoe arrangement, commonly
rolling friction and it is this friction which known as the "foundation brake," must be
must actually stop the vehicle. Should the controlled with some form of "brake
brakes overcome rolling friction to the actuating system." With drum brakes, the
extent that any wheel is locked, all of the shoes are forced against the drum by
heat produced is confined to the small skid pistons under fluid pressure. To assist or
area of the tire. More time and distance is supplement manual operation, the system
required to stop the vehicle, control is lost, may include a power unit operated by
and tire wear is increased. Therefore, vacuum or compressed air. Cam-operated
many manufacturers now equip their brake shoes are actuated mechanically
vehicles with an anti-lock type brake and, in modern usage, are found on heavy
system. trucks and trailers equipped with air or
vacuum-powered brake actuating systems.
b. Coefficient of Friction. The stopping
distance is influenced by the road's Stopping Torque.
c o ef f ic ie n t o f f rict io n , wh ic h is
approximately 60 percent on dry concrete, The amount of stopping torque developed
less on asphalt, still less on gravel, and by a foundation brake of given type and
quite low on wet or icy surfaces. This size depends upon the amount of
maximum brake retarding effect of the road controlling actuating force being used. It
is one of the forces which determines the also depends upon built-in factors such as
amount of deceleration, often called the "K" the amount of shoe energization, amount of
percent of the weight being stopped. A 0.60 shoe leverage, and characteristics of the
"K" stop (60 pounds retarding force per 100 brake lining.
pounds of weight) is the approximate limit
of present highways. Shoe Energization Factor.
c. Tire Diameter. Tire diameter is also a When shoes contact the drum, the friction
factor, since leverage between the brake drag tends to rotate each shoe about the
and wheel is reduced by increases in the hinge point (anchor), When this shoe
rolling radius. Therefore, the amount of friction presses the shoe lining into tighter
brake torque capacity (stopping power) contact with the drum, it acts as a
needed depends primarily upon gross "self-energizing" force which is added to the
actuating force to assist the braking can result in a "pull" which swings the
operation. Conversely, if the drag tends to vehicle to the opposite side when brakes
force the shoe away from the drum, it are applied if the brake on the opposite
resists the actuating force and is described wheel is operating normally. Likewise, when
as a "de-energizing" force. Self-energized concentrated too near the shoe toe, the
shoes are frequently referred to as brake will "grab" and pull the vehicle toward
"forward," "leading" or "primary" shoes and the side on which the grabbing brake is
the de-energized shoes as "reverse" or located.
secondary "trailing" shoes. All drum type
brakes make use of these energization Drum De flection and Thermal
principles in varying degrees. Expansion.
automotive uses demanding a durable, history would fill several large volumes,
superior performance. Brake linings with therefore, a great deal of material has been
these characteristics require the most omitted.
accurate shoe alignment and initial
adjustment and break-in. CHAPTER 4 - PASSENGER VEHICLE
BRAKE SYSTEMS
d. Shoe-Lining Attachments. The three
methods currently used to attach lining HYDRAULIC SYSTEM
to brake shoes are:
General.
(1) Bonding. This method utilizes special
sheet or liquid adhesives to bond the Passenger cars and light trucks are
lining directly to the shoes. This method universally equipped with a hydraulic
requires heat and special pressure system for operation of the service brakes.
equipment to properly bond shoe and The major components of the hydraulic
lining. system include application pedal, master
cylinder assembly, brake fluid, fluid
(2) Riveting. Rivets of the semi-tubular distribution lines (tubing or hoses), and
type anchor the lining to the brake shoe. individual wheel cylinder or caliper
Soft rivets are used for their easy assemblies. The system may also include
crimping qualities and the selection of a power-assist feature to supplement
correct size, type and method of riveting pressure applied manually to the system
is very important to ensure that the lining and an anti-lock feature that prevents wheel
is firmly and evenly anchored to the shoe. lock-up during hard braking.
Conclusion. The material presented in this The force applied by the hydraulic system
chapter briefly reviews the history and is self-equalizing upon brake pedal
fundamentals of the modern motor vehicle application. Since the pressure is normally
drum brake. A complete review of the
manufacturer’s recommendations. (All cups have a source of clean, dry compressed air
and seals also should be replaced.) Do to prevent contamination of the fluid.
NOT use “used” brake fluid.
MASTER CYLINDER.
Handling and Storing.
Description.
The following basic rules should be applied
when handling and storing brake fluid. The master cylinder is a form of hydraulic
pump operated by the brake pedal through
a. Keep the brake fluid clean. Do not get a link or push rod. A typical master cylinder
any foreign material in the fluid. consists of a cylinder, a piston with a
primary and secondary cup, a residual
b. Be careful to keep any petroleum pressure check valve, a return spring and a
product (gasoline, kerosene, oil, grease, fluid reservoir.
etc.) or moisture from getting into the brake
fluid. Operation.
c. Use only clean containers for When force is applied to the brake pedal,
dispensing brake fluid. Do not use the force is multiplied by the pedal lever
containers contaminated with dirt, oil, and transmitted through the push rod or link
grease, water, rust, etc. to the master cylinder piston. The piston
converts the force into hydraulic fluid
d. Always cover or cap brake fluid pressure. Hydraulic fluid under pressure is
containers when not actually dispensing the forced through the check valve and
fluid. hydraulic lines into the wheel cylinders to
expand the shoes against the drums. When
e. Brake fluid is a hazardous material and the brake pedal is released, the brake shoe
therefore, it must be discarded in a manner return springs force the fluid through the
consistent with environmental laws and hydraulic lines and residual check valve
regulations. back into the master cylinder. The
compensating port is reopened when the
f. Store brake fluid containers in a clean, master cylinder piston reaches the full
dry place. release position. When the brake pedal is
released quickly, the master cylinder piston
g. Clean, dry compressed air is essential may return faster than the fluid from the
in air operated pressure bleeding wheel cylinders. If this happens, fluid from
equipment. Residue from air lines, misted the reservoir enters the cylinder through the
oil and water can be picked up from the inlet port to keep the chamber ahead of the
compressor tank. If the equipment for piston full of fluid. As the wheel cylinder
pressure bleeding does not provide positive pistons return to the fully released position,
separation of the compressed air from the the excess fluid in the system is returned to
brake fluid, means must be provided to
Many passenger cars and light trucks have There are numerous types of drum brakes,
power-assisted brake systems. A unit each given a name descriptive of its design.
powered by vacuum from the intake Drum-type brakes are generally classified
manifold provides force supplementing as "Servo" or "Non-Servo" types. The
manual pressure on the hydraulic system. servo-type is also known as the "compound
Two of the three types of power units shoe" type.
supplement manual pressure applied to the
master cylinder and one type of unit boosts Operation.
hydraulic pressure applied by the master
cylinder to the wheel cylinders. The brake shoes are anchored to a backing
plate rigidly attached to the axle housing or
Types of Systems. wheel suspension unit and the drum rotates
with the wheel. Fluid pressure forces the
The three basic types of vacuum power wheel cylinder pistons to move the brake
brake units are as follows: shoes toward the rotating drum. As the
brake shoe linings contact the drum,
a. Integral Type. The integral type braking action is applied. Upon release of
supplements manual pressure to the the hydraulic pressure, coiled springs return
master cylinder and is any type power the brake shoes to the unapplied position.
brake unit having the master cylinder
assembly mounted directly on the vacuum Braking Force.
chamber.
All the brakes on a vehicle are designed to
b. Pedal Assist Type. The pedal-assist be applied equally since they normally
type power brake unit applies force to the receive the same hydraulic pressure. (As
brake pedal linkage to supplement previously noted, disc/drum and disc/disc
pressure applied manually to the master systems use a proportioning valve that
cylinder. The hydraulic master cylinder is distributes pressure proportionately front
independent of this type of power brake and rear.) However, the amount of braking
unit. force upon a wheel is determined by the
diameter of the wheel and master cylinders,
c. Pressure Multiplier Type. The and/or the size of the brake drum and
pressure multiplier type of power brake unit shoes.
has a self contained hydraulic cylinder
known as a "slave" that works in Self Energizing Brakes.
conjunction with, and is actuated by, the
master cylinder on the vehicle to boost Some drum-type brakes are designed to
hydraulic pressure to the wheel cylinders. use the rotating force of the drum to assist
Used With Power Assisted Systems. Brake pad assemblies fit into the caliper
housing and rest on the metal tabs that are
Most late model passenger cars and light located at each end of the steel portion of
trucks are equipped with power assisted the brake pad. Hydraulic force applied
disc/drum or disc/disc brake systems. In against the cylinder pistons moves the pads
addition, many manufacturers equip their in the caliper housing toward the rotor
vehicles with an anti-lock system on either surfaces. A brake pad assembly consists of
the rear brakes or on all brakes. friction material, a steel plate, guide pins,
and mounting clips.
To protect against foreign matter, a metal Automatic adjustment of the brake pads is
splash shield may be fastened to the top of obtained by the piston movement past the
the caliper housing. These splash shields seals as brake lining wear takes place.
must be installed properly to assure proper Clearance is continually controlled between
brake pad movement. the friction material and rotor assembly as
the piston changes its position with respect
Splash Plate. to the seal. Parallelism and lateral run-out
of the rotor must be within manufacturer’s
The disc brake assembly may be further specifications to maintain the proper pedal
protected from water and contamination by reserve and prevent brake pedal pulsation.
a splash plate located at the inboard side. Pads may have wear indicators that will
This may be compared to the backing plate contact the rotor surface when the brake
of the shoe and drum brake. The wheel linings are worn sufficiently thin, warning
assembly protects the outboard side. Any the driver that the brake pads require
liquid or foreign matter hitting the rotor replacing.
surfaces would tend to be discarded by
centrifugal force as the rotors revolve. ANTI-LOCK BRAKES
During a brake application, the caliper Anti-Lock systems are also known as ABS.
bores receive hydraulic pressure from the Some ABS systems are also part of the
master cylinder through hydraulic lines, vehicle traction control system (TCS).
cross-over tubes, and internal passages. Inspection, diagnosis, system bleeding,
This hydraulic pressure in the bore then depressurizing, testing, and service
forces the pistons against the brake pads procedures will vary. Refer to the specific
and applies force to the rotor surfaces. vehicle manufacturer’s service manuals for
Braking action then takes place. As the the correct inspection, test, and repair
hydraulic system is pressurized, the square procedures.
section of the rubber sealing ring in each
cylinder bore tends to distort in the applied W arning: Failure to properly
direction as the pistons move the brake depressurize ABS before working on the
shoes toward the rotor. When hydraulic system may cause physical injury and/or
pressure is released, the distorted seals component damage. Refer to the
return to their normal position causing the s pe c i fi c ve h i cl e m a nufa c tur e r ’ s
pistons to retract in the cylinder bores. The instructions.
pads stay in near contact with the rotors.
Anti-lock brake systems apply force many
times per second to maintain tire speed at
Note the vehicle tire size. The modulator assembly executes the
commands provided by the electronic
Installing a tire size other than the one control module to control hydraulic pressure
recommended by the vehicle manufacturer to each wheel or axle.
may adversely affect the sensitivity of the
anti-lock system. Anti-Lock Brake System Indicator Light.
ABS systems are not designed to function Vehicle manufacturers use various anti-lock
until enough force is applied to either lock system indicator lights. Some vehicles
or nearly lock the wheels. During normal have more than one light. The purpose of
braking, the ABS system remains ready, these lights are to alert the driver if the
but does not operate. If the ABS system system is not functioning properly.
fails, usually the vehicle’s brakes continue
to function as though the vehicle was not PARKING BRAKES
equipped with ABS. However, a warning
light should illuminate on the instrument Description.
panel alerting the driver of a malfunction.
The parking brake is a hand or foot
In addition to the components listed for operated mechanical brake for holding the
disc/drum systems, most anti-lock brake vehicle stationary while parked. There are
systems also have the following two basic types of parking brakes - the
components: integral type, which is a part of the regular
service brakes; and the transmission or
Electronic Control Module. drive shaft type, which is independent of
the wheel brakes. Systems that apply
The electronic control module provides hydraulic pressure to the service brake
application management information for the
system do not suffice as a legal parking of its travel or when the parking brake fails
brake. to release. These conditions may be
caused by wear, grease on the linings,
Integral Type. linkage out of adjustment, damaged parts
or lack of lubrication. Worn linings,
Most integral type parking brake systems damaged parts or a scored drum should be
consists of a parking brake lever or pedal replaced. When binding occurs, linkage
mechanism in the driver's compartment should be lubricated and adjusted or
and a cable and conduit system which repaired if necessary.
connects to the parking brake levers in the
rear wheel brakes. When the parking brake CHAPTER 5 - TYPICAL BRAKE
lever is applied, the parking brake cables ADJUSTMENT-INSPECTION
apply a balanced and equalized pull on PROCEDURES FOR PASSENGER CARS
both wheel parking brake levers. The levers AND LIGHT TRUCKS
then move linkage to force the brake shoes
or pads against the brake drums or rotors. CHECK OUT PROCEDURES
Before starting to check out the brake f. Dash Warning Lights. Most vehicles
system itself, the following related equipped with anti-lock brakes are also
components on the vehicle should be equipped with a lamp in the dash to warn
inspected. If a non-brake related item is the driver of an anti-lock system
found defective, but does not affect the malfunction. Therefore, when servicing a
vehicle’s ability to stop in a straight line or vehicle with an anti-lock brake system,
within the specified distance, a certificate check to see if any brake related dash
may be issued without repairing the defect. warning lamps are illuminated, indicating
However, the customer should be informed that an anti-lock trouble code may be
of the defect and a notation of such stored in the computer.
defect(s) written on the work order.
Most vehicles manufactured after the mid
a. Tires. Check tire pressures to ensure 1960s are also equipped with a red warning
they are properly inflated. Tires on the light in the dash. The purpose of this light
same axle should have the same tire is to warn the driver of a fault with the
pressure, tread pattern, and size. Also, vehicle brake system.
radial and bias or bias belt tires should not
be intermixed. If the dash brake warning lamp or ABS
lamp is lit, check the vehicle manufacturer’s
b. Wheel bearings. Loose wheel recommendations before proceeding. If the
bearings may allow a brake drum or rotor to manufacturer indicates that a lit warning
lean to one side, causing uneven brake lamp represents a condition that will/could
shoe contact and erratic braking. cause the vehicle’s service brake system
b. Brake Pedal Check. cylinder. If the level is low, fill the master
cylinder and repeat the test. If the reserve
(1) Depress the Brake Pedal. If the is still not built up, it is an indication that
pedal locks or binds, make needed the master cylinder cup has failed or that
repairs before proceeding with the the brake system has a severe leak. If the
inspection. Check for loose master pedal feel is "spongy," it is an indication of
cylinder mounting and binding linkage air in the hydraulic system.
(including power booster linkage, when
used). (5) Check for External Leakage. If a
pedal reserve is present, hold the pedal
(2) Check Hydraulic Brake Pedal Free down hard for a period of one minute. If,
Play. A minimum amount of free play instead of remaining stable, the pedal
should exist, enough to make sure the moves down, lessening the reserve, it is
piston is fully returned and does not block an indication that the hydraulic system is
the master-cylinder compensating port leaking fluid.
(except on certain vehicles without a
separate pedal return spring). Refer to (6) Check Internal Leakage. After
manufacturer’s specifications. holding the brake pedal down hard,
lessen foot pressure without completely
(3) Depress the Brake Pedal. The brake releasing the pedal. Then depress the
pedal should be depressed slowly until it pedal again gradually with light foot
can be depressed no further. If pedal pressure. If the reserve gradually fades
pressure builds up, drops off sharply, under light foot pressure, hydraulic fluid
then builds up again as the pedal moves may be leaking past the master cylinder
downward, it is an indication that a piston primary cup lip causing pressure to be
is sticking in one or more wheel cylinders dissipated within the cylinder. If this
or that one of the hydraulic lines is should be the case, no external leak
partially blocked. Such blocking would be would be noticed, since the fluid would
more likely to occur in a flexible hose due remain in the master cylinder. Power
to flaking or separation of inner layers. assisted and anti-lock system test
procedures may vary. Refer to the
(4) Check Pedal Reserve. If the pedal vehicle manufacturer’s test procedures.
moves downward past the point of
reserve (1/2 to 2/3 of the possible stroke), (7) Check for Dragging Brakes. If after
check the brake adjustment and repeated brake applications (not pumped)
thickness of the vehicle’s brake lining. If, the pedal reserve increases and brakes at
in a hydraulic system, the brake can be all wheels begin to drag, it indicates a
depressed to the floor, pump the system blocked master cylinder compensating
by rapidly pumping the pedal several port, due to a swollen primary cup, lack of
times to determine if a reserve can be necessary pedal lash, or dirt.
built up. If there is still no reserve after
pumping, check fluid level in the master (8) Check Vacuum Braking. If the
vehicle is equipped with a vacuum assist Disc brake inspection usually requires
brake, stop the engine and depress the removal of the wheels; however removal
brake pedal several times to eliminate the of the rotors is not usually required. If the
vacuum reserve. Depress pedal hard, rotor is removed, on reassembly the rotor
and while holding it start the engine. If the retaining nut must be torqued to
power unit is working, the pedal should manufacturer’s specifications for proper
drop appreciably under foot pressure. wheel bearing clearance.
(9) Check Parking Brake. Apply (2) Hub. Examine wheel bearing races
parking brake to check amount of travel and general condition of bearings.
and feel of the lever. The brake should Grease, other than in the wheel hub,
apply firmly, well before the hand or foot suggests a leaking seal.
lever reaches its limit of travel. The
adjustment should permit the brake (3) Toothed Ring, Sensor and Wiring (if
applying lever to travel approximately equipped). Check for broken, bent, or
one-half of its maximum range. The missing teeth on the toothed ring. Check
parking brake shall be adequate to hold sensor adjustment, wiring connectors,
the vehicle or combination of vehicles wire routing and condition.
stationary on any grade on which it is
operated under all conditions of loading (4) Caliper. Check the caliper for damage
on a surface free from snow, ice or loose and inside leakage and at piston seals.
material. In any event, the parking brake Check for leakage at inlet and crossover
shall be capable of locking the braked connections. Check for elongated or worn
wheels to the limit of traction. guide pins, mounting holes, cracks in the
casting, worn mounting surfaces, etc.
(10) Move Vehicle and Check a Stop. Verify that floating type calipers slide
At this point it is advisable to move the freely from side to side.
vehicle and try an easy, rolling stop.
"Pedal fight" (uncomfortable vibration (5) Mounting Bolts. Check for loose or
against the foot) during brake application damaged mounting bolts or guide pins
is an indication of out-of-round drums and for loose or missing shoe retaining
requiring reconditioning. This reaction will pins or clips.
be minimized if the vehicle is equipped
with power brakes. (6) Splash Shield. Check splash shield
for damage or looseness.
c. Disc Brake Inspection.
(7) Linings. Check pad linings for proper
(1) Wheel Removal. Before removing thickness. Generally, the lining should be
any wheels, rock all wheels to check for more than 1/32" thick for bonded or more
any looseness or indications revealing than 1/64" above rivets on riveted linings,
improper wheel bearing adjustment, worn or follow the m anuf a ctu rer’s
ball joints,or worn tie rod ends, etc.
Before you reline any brakes, measure 1 1/4" through 1 7/16" i.d. = 0.007"
the drum diameter with a micrometer. It is
recommended that you do not machine a 1 ½" and larger = 0.008"
drum to exceed the maximum diameter
as identified on the drum. It is also If the piston can be inserted with the shim
recommended that an older drum not in place, the cylinder is oversize and
identified with a maximum drum diameter should be replaced or resleeved.
should not be machined to exceed 0.060
inches inside diameter over its original (5) Check Springs and Hold-Downs.
size. If the vehicle or brake parts Damaged retraction springs, hold-downs,
manufacturer provides a specification, and other visible abnormalities should be
such specification may be used. This noted.
recommendation applies to light-duty
passenger vehicles, including light trucks. (6) Check Backing Plates and Anchors.
Loose, bent, or distorted shoe pads and
(4) Check Hydraulic Wheel Cylinder. galled anchors should be replaced. Rusty
Any stains suggest fluid leaks. The or dirt-coated shoe pads suggest an
rubber boots should not be brittle or alignment fault. If wear marks on
cracked. (Do not disturb boots unless alignment pads exceed 0.005" in depth,
identified as part of the manufacturer’s they should be resurfaced or replaced.
procedure.) The actual presence of fluid,
other than mere dampness, indicates a (7) Condition of Automatic Adjusters
fluid leak. Therefore, leaking wheel and Parking Brake Linkages, When
cylinder(s) must be rebuilt or replaced. Used. Always check an automatic
When you rebuild a wheel cylinder, be adjuster pawl, engaging a star wheel.
sure to clean the cylinder bore and Poor alignment will hinder adjustment.
inspect it for scoring, pitting, and Parts should be cleaned, lubricated, and
corrosion. Follow manufacturer’s adjusted to allow movement as designed.
specifications and recommendations for
wheel cylinder honing or replacement (8) Condition of Wheel Bearings and
procedures. Check the clearance Grease Seal. Examine wheel bearing
between the cylinder bore wall and the races and general condition of bearings.
piston by placing a strip of feeler shim Grease, other than in the wheel hub,
lengthwise between the cylinder bore and suggests a leaking seal.
piston. The feeler shim should be 1/4"
wide and the following measurements
(9) When Inspection Reveals No Fault. (2) Leaks. Inspect outside of backing
If inspection reveals no fault, replace plate, drum and inner sidewall of the tire
drum and wheel and perform the brake for stains and dampness which would
adjustment. A variation in drag suggests indicate leakage of hydraulic brake fluid,
an out-of-round drum. If any out-of-round wheel bearing grease, or gear oil. In
condition seems extreme, remove that some cases the nature of a leak can be
wheel and drum for another inspection. determined by the odor of the residue.
e. Parking Brake Check. (3) Tubes and Hoses. Inspect tube and
hose connections for stains around
(1) Cables. If rear brakes are equipped fittings or wet spots around hoses which
with a parking brake mechanism, pull on indicate fluid leakage. Tighten these
cables by hand to determine if they are connections. Replace all damaged tubes
free and if brakes can be applied and and hoses. Some hoses are held in
released by manipulating the cables. position by a suspension spring; if these
Adjust parking brake cables to remove springs have been damaged or lost,
any excess slack caused by adjustment replace them.
of the service brakes. Lubricate if
specified by the manufacturer. (4) Hydraulic Lines. On hydraulic brake
lines, follow the tubes back to the master
(2) Drive-Shaft. Where a drive-shaft cylinder while checking for indications of
parking brake is used, check visually for leaks, dents, kinks, damaged fittings
condition of brake and operating cable. and/or hold-down clips.
Apply the hand-brake lever to determine
if adjustment is correct. g. Driving Test Procedures and Con-
ditions.
f. Chassis Inspection.
(1) "Dive" Condition. "Dive" is the result
(l) Suspension. Perform a visual of braking torque being imparted into the
inspection to determine the general vehicle suspension system, tending to
condition of chassis parts such as cause the front end to "dip," which is a
springs, shock absorbers, torsion normal reaction to braking. When dive
suspension rods, steering linkage, etc. seems abnormally heavy or “one sided,"
Check for any faults which might affect it will be due to a pull or grab if the brakes
brake performance. are at fault. However, it is generally better
to check the condition of front steering
A Certificate of Adjustment cannot be and suspension before performing
withheld for a defective suspension part extensive brake work.
unless it directly affects vehicle’s brake
performance; however, the customer (2) "Pull" and "Grab" Conditions. "Pull"
should be informed of any defects found. or "grab" is often the symptom of some
FMVSS 121 applies to all trailers b. More Complicated Systems. While all
manufactured and sold after January 1, air brake systems generally perform the
1975, and all motor vehicles after March 1, same basic functions, many variations in
1975. Many manufacturers began the design of individual components and
equipping vehicles to comply with FMVSS their arrangement in the system may be
121 prior to the effective dates. encountered (See Figure 4).
(1) The service brakes are air-applied and be applied by the operator in the case of
spring-released while the spring brake failure in the service air brake systems.
e m e r g e n c y s t o ppin g s ys t e m is Most emergency systems, which also
spring-applied and air-released. Energy to serve as the parking brake, consist of a
operate the brakes is provided by check valve, a protected air reservoir, a
compressed air from an engine-driven air dash-control valve and spring-applied,
compressor. The air pressure for the air-released brake actuators referred to
service brake system is stored in as spring brakes. The check valve
reservoirs, and the pressure in the protects the reservoir from a pressure
reservoirs is controlled by the air loss in the event of a decrease of
compressor governor. The service brakes pressure in the service air brake system.
are applied by the driver depressing the
foot valve which permits air pressure to (4) A spring brake unit is a device which
flow through the various brake lines to air generally consists of a cylinder
brake chambers at the wheels. The (chamber), spring and piston. The springs
system may also include a relay valve to are compressed and held in the released
speed the application and release of air position by air pressure and automatically
pressure at the wheel air chambers. apply the brakes when air pressure in the
chambers is reduced to a point below that
Operation of the foot valve provides a force exerted by the springs. This may
modulated air signal to the relay valve occur either by a reduction of pressure in
which provides an equally modulated the protected reservoir or by operation of
application of air pressure to the air the parking/emergency brake dash
chambers from the service air reservoir. control valve which shuts off and vents
the control line, exhausting the air in the
(2) The driver can elect to either apply the chambers.
trailer service brakes alone by operating
the hand-control valve, or when he/she (5) When the compressor supplies air to
steps on the foot pedal valve, air is the service brake reservoirs, air is also
applied not only to the tractor brakes but automatically delivered to the protected
is also routed through the double check emergency reservoir. Upon operation of
valve, through the tractor protection valve, the parking-emergency brake control
and the service line gladhand connection valve, air pressure from the protected air
to the relay emergency valve on the reservoir goes through the control valve
trailer, which applies air pressure from the and the quick-release valve to the spring
trailer reservoir to the brake chambers at brake chambers and compresses the
the trailer wheels. springs, releasing the brakes.
(3) Air brake systems consist of many (6) If this motor vehicle is designed to tow
safety devices; vehicles with air brakes a trailer, the brake system is equipped
are required to be equipped with with a tractor protection valve. This valve
emergency stopping systems which may is another safety device which will retain
the motor vehicle's air supply in the event trailer reservoir to the trailer brake
of an excessive decrease in pressure in chambers when the trailer service brakes
the trailer's emergency (supply) line. A are applied by either the foot valve or the
tractor protection valve automatically hand valve which controls the trailer
shuts off the air supply to both trailer air brakes. The emergency function of this
lines when the service air pressure in the valve automatically applies air pressure to
towing vehicle's air system is reduced to the trailer service brake chambers when
a fixed pressure, typically between 20 the air in the emergency (supply) line
and 45 psi. This shut-off may also be drops below a predetermined pressure or
performed manually by operation of the upon a sudden decrease in pressure in
valve's dash control to exhaust the air in this line, either accidentally or upon
the trailer supply line. Closing of the manual venting by operating the tractor
valve, either automatically or manually, protection valve.
and the venting of air pressure from the
emergency air line automatically actuates (9) Some air brake systems may have
the emergency function of the trailer's devices such as filters or after coolers
relay emergency valve, thereby applying installed in the compressor discharge line
the trailer brakes. Either the automatic or to clean and cool the air from the
manual reopening of the tractor protection compressor, a front-wheel limiting valve
valve permits air pressure to again charge to limit the amount of air pressure applied
the emergency supply line, flowing to the front brake chambers during
through gladhand connectors and the inclement weather, and numerous other
trailer relay emergency valve into the devices.
trailer reservoir and releases the brakes.
WHEEL BRAKE ASSEMBLIES.
(7) Another required safety device is a
low pressure warning device. The device There are three basic types of air operated
shall be readily visible or audible to the wheel brake assemblies for large trucks
driver and shall give a satisfactory and trailers.
continuous warning when the air supply
pressure drops below a fixed pressure, (1) S-Type Cam Brake. The most
which shall not be more than 75 pounds common type of wheel brake assembly is
per square inch nor less than 55 pounds referred to as the S-type cam brake. With
per square inch with the engine running. this type, the brake shoes are applied
This is considered the minimum for safe against the drum by an S-type cam
operation of the vehicle's service brakes. installed on one end of a shaft which is
rotated by a lever attached by a pushrod
(8) The trailer relay emergency valve to the service air brake chamber. The
functions as both a relay valve and an brake shoes on this type of wheel
emergency feature of the trailer's air assembly are adjusted for wear by the
brake system. This valve normally works use of the lever as a slack adjuster. Some
as a relay valve to apply the air from the slack adjusters have a feature of
audible. Continue running the engine until system and a parking brake system
the governor cuts out and observe the (VC26450).
pressure gauge reading. With the engine
idling, reduce the pressure in the system by e. Parking brake is not adequate to hold
making a series of brake applications and vehicle under all load conditions
observe the pressure at which the governor (VC26451).
cuts in. With the system fully charged, stop
the engine and check for air leakage by f. Service brakes are not in good
recording the pressure drop in pounds per serviceable condition (VC26453).
square inch (psi) per minute with brakes
released and also with the brakes fully g. Brakes not sufficient to control the
applied. Inspect for restricted, abraded, movement of and to stop vehicle(s) under
collapsed, improperly supported, or broken all conditions of loading on any grade on
hoses and tubes and audible leaks. Check which it is operated (VC26454).
the safety valve for freedom of action. If
the compressor is belt driven, check the h. Vehicle does not pass the stop test
belt for tightness and observe the belt per VC 26456.
condition.
i. Air brake system is not capable of
Inspect and Do Not Certify if: providing full service brake application as
specified in VC 26502.
a. Brake light(s) does not operate at the
rear of the vehicle / trailer (VC 24603). j. Air compressor governor cut-in
pressure is lower than 80 psi or cut-out
b. Breakaway brakes fail to operate pressure is higher than 150 psi (unless
correctly. Power brakes on any trailer or other values are provided by the vehicle
semitrailer manufactured after December manufacturer (VC26503).
31, 1955, and required to be equipped
with brakes shall be designed to be k. Air pressure gauge does not read
automatically applied upon breakaway within 10 percent of the actual system
from the towing vehicle and shall be pressure (VC26505).
capable of stopping and holding such
vehicle stationary for not less than 15 l. Vehicle air pressure gauge does not
minutes (VC26304). function as required (VC26505).
The California Vehicle Code (Section 580) a. Disassemble the service brake system
describes a “specially constructed vehicle” to allow verification of the thickness of the
as a vehicle which is built for private use, brake friction material on all wheels.
not for resale, and is not constructed by a Inspect the drums and/or rotors for
licensed manufacturer or remanufacturer. dimensional compliance to the vehicle or
A specially constructed vehicle may be built brake system manufacturer's
from (1) a kit; (2) new or used, or a specifications. Examine all exposed service
combination of new and used, parts; or (3) brake components for physical damage,
a vehicle reported for dismantling, as leaks, wear, or heavy corrosion. Verify that
required by Section 5500 or 11520, which, components match side to side.
when reconstructed, does not resemble the
original make of the vehicle dismantled. A b. Verify that the brake pedal travel is
specially constructed vehicle is not a within reason. There are no written
vehicle which has been repaired or specifications in the Vehicle Code,
restored to its original design by replacing however, when depressing the pedal, it
parts. should become firm before reaching half of
its full travel and must stop the vehicle
Description of a Remanufactured within the distance as listed in the Vehicle
Vehicle. Code.
A “remanufactured vehicle” (Vehicle Code c. Check the parking brake for proper
Section 507.5) is a vehicle that has been operation.
constructed by a licensed remanufacturer
and consists of any used or reconditioned d. Ensure that the stop lights are
integral parts, including, but not limited to, functioning properly.
frame, engine, transmission, axles, brakes,
or suspension. Remanufactured vehicles e. Road test the vehicle to determine
may be sold under a distinctive trade name. stopping distance.
An existing vehicle which is incidently
repaired, restored, or modified by replacing f. Inform the customer of any marginal or
or adding parts or accessories is not a defective conditions found during the
remanufactured vehicle. inspection.
service limits, (2) the thickness of the brake Adjusters. However, this handbook is not
lining (friction material) is found to be less all inclusive; therefore, station owners and
than that specified in this handbook or adjusters must use acceptable reference
manufacturer's service limits, (3) the manuals or electronic media to obtain the
vehicle fails to stop within the required necessary vehicle or legal data. It is the
distance, (4) the parking brake system is station owner and adjuster’s responsibility
found to be inoperative, (5) the brake lights to follow lawful procedures when
are inoperative, or any other condition is performing brake work and issuing
found that would make the service braking Certificates of Compliance - Brake
system unsafe. Adjustment. References that adjusters
should use include the California Vehicle
Certification Criteria Code, available from the Department of
Motor Vehicles (DMV), Title 13 (excerpted
Do not certify the vehicle if (1) any drum or sections) and Title 16 of the California
rotor exceeds the vehicle or parts Code of Regulations, listed in the BAR
manufacturer's service limits, (2) the Laws and Regulations booklet available
thickness of the brake lining (friction free of charge from BAR. The Vehicle
material) is found to be less than that Code is also available on the Internet at
specified by the manufacturer's service www.leginfo.ca.gov. Titles 13 and 16 of the
limits, (3) the vehicle fails to stop within the California Code of Regulations are
required distance, (4) the parking brake available at www.oal.ca.gov.
system is found to be inoperative, (5) brake
components don’t match side to side or any Filling Out The Official Certificate
other condition is found that would make
the service braking system unsafe. Use the example on page 40 to fill out the
Official Certificate of Compliance - Brake
CHAPTER 8 - BRAKE EQUIPMENT Adjustment. Call the local BAR field office
REQUIREMENTS AND REFERENCE if additional information is required.
DATA