by

Russell Krick

Publisher
The Goodheart-Willcox Co., Inc.
Tinley Park, Illinois

© Goodheart-Willcox Co., Inc.

© Goodheart-Willcox Co., Inc.
  Basic brake system
 Braking ratio
 Brake system hydraulics
 Brake system components
 Parking brakes

© Goodheart-Willcox Co., Inc.

 Automotive Brakes
 Provide a means of using friction to
either slow, stop, or hold the wheels of
a vehicle
 When a car is moving, it has energy
stored in the form of inertia (kinetic
energy)
 To stop the vehicle, the brakes convert
kinetic (moving) energy into heat

© Goodheart-Willcox Co., Inc.

© Goodheart-Willcox Co., Inc.
 Brake Operation
 When the driver pushes on the brake
pedal, lever action pushes a rod into
the brake booster and master cylinder
 Pressure developed in the master
cylinder forces fluid through the brake
lines to the wheel brake assemblies
 Brake assemblies use this pressure to
cause friction for braking

© Goodheart-Willcox Co., Inc.

 Parking Brake
 Parking brake system uses cables or
rods to mechanically apply the rear
brakes
 Provides a system for holding the
wheels when the vehicle is parked, or
stopping the vehicle during complete
hydraulic brake system failure

© Goodheart-Willcox Co., Inc.

 Drum and Disc Brakes
 Two common types of brake
assemblies:
 Disc brakes
often used on the front wheels
 Drum brakes
often used on the rear wheels

© Goodheart-Willcox Co., Inc.

 Drum and Disc Brakes

Disc brakes Drum brakes

© Goodheart-Willcox Co., Inc.

  Comparison of front wheel braking
effort to rear wheel braking effort
 When a vehicle stops, its weight tends
to transfer onto the front wheels
 Rear tires lose some of their grip
 Front wheels must do more of the
braking

© Goodheart-Willcox Co., Inc.

 Typical Braking Ratios
 Rear wheel drive vehicles:
front brakes may handle 60% to 70% of
the braking, rear brakes handle 30% to
40%
 Front wheel drive vehicles:
more weight is concentrated on the front
wheels
braking ratio is even higher at the front
wheels

© Goodheart-Willcox Co., Inc.

  Automotive brakes use a hydraulic
system
 Hydraulic brakes use a confined brake
fluid to transfer brake pedal motion and
pressure to each of the wheel brake
assemblies

© Goodheart-Willcox Co., Inc.

 Hydraulic Principles
 Liquids in a confined area will not
compress
 When pressure is applied to a closed
system, pressure is exerted equally in
all directions
 Hydraulics can be used to increase or
decrease force or motion

© Goodheart-Willcox Co., Inc.

 Hydraulic System
Action
 Pressure and motion can be
transferred from one cylinder to
another
 Cylinders of the same size:
if one piston is moved, the other will move
the same amount with the same force
 Cylinders of different size:
if the smaller piston is moved, the larger
piston will move with more force but will
move a shorter distance
© Goodheart-Willcox Co., Inc.
 Hydraulic System
Action
In a hydraulic jack, a
small piston acts on a
large piston, resulting
in great force, but a
small amount of
movement

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 Hydraulic System
Action

Hydraulic jack operation

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 Hydraulic Brake Action
 Master cylinder acts on the pumping
piston that supplies system pressure
 Wheel cylinder acts as the power
piston, moving the friction linings into
contact with the rotating drums or discs

© Goodheart-Willcox Co., Inc.

 Hydraulic Brake Action

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© Goodheart-Willcox Co., Inc.
 Brake Pedal Assembly

Acts as a lever to increase the force

applied to the master cylinder piston
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 Master Cylinder
 Foot operated pump that forces fluid to
the brake lines and wheel cylinders
 Develops pressure to apply the brakes
 Equalizes pressure required for braking
 Keeps the system full of fluid as the
linings wear
 May maintain a slight pressure to keep
contaminants from entering the system

© Goodheart-Willcox Co., Inc.

 Master Cylinder

Brakes applied Brakes released

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 Master Cylinder
Components

© Goodheart-Willcox Co., Inc.

 Master Cylinder
Components
 Cup and piston
used to pressurize the system
when they are pushed forward, they trap
fluid, building pressure
 Intake port
allows fluid to enter the rear of the
cylinder as the piston slides forward
fluid flows from the reservoir, into the area
behind the piston and cup
© Goodheart-Willcox Co., Inc.
 Master Cylinder
Components
 Compensating port
releases pressure when the piston returns
to the released position
fluid can flow back into the reservoir
through the compensating port
 Residual pressure valves
maintain residual fluid pressure of
approximately 10 psi (69 kPa) to help
keep contaminants out of the system

© Goodheart-Willcox Co., Inc.

 Master Cylinder
Components
 Rubber boot
prevents dust, dirt, and moisture from
entering the back of the master cylinder
 Reservoir
stores an extra supply of brake fluid
cast as part of the housing or a removable
plastic part

© Goodheart-Willcox Co., Inc.

 Piston and Cup

© Goodheart-Willcox Co., Inc.

 Residual
Pressure
Valve
Brakes applied, fluid
flows freely

Brakes released, valve

closes to restrict the
return of fluid to the
master cylinder
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 Dual Master Cylinder

© Goodheart-Willcox Co., Inc.

 Dual Master Cylinder
 Uses two separate hydraulic pistons
and two fluid reservoirs
 Each piston operates a hydraulic circuit
that controls two wheel brake
assemblies
 If there is a leak in one of the hydraulic
circuits, the other circuit can still
provide braking action on two wheels

© Goodheart-Willcox Co., Inc.

 Dual
Master
Cylinder

© Goodheart-Willcox Co., Inc.

 Dual Master Cylinder
(Normal Operation)

Both pistons produce pressure to all four

wheel brake assemblies
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 Dual Master Cylinder
(Rear Brake Circuit Leak)

Primary piston pushes on the

secondary piston, two wheel brake
assemblies still work
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 Dual Master Cylinder
(Front Brake Circuit Leak)

Secondary piston slides forward,

primary piston operates two
wheel brakes normally
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 Power Brakes
 Use a booster and vacuum or hydraulic
pressure to assist brake pedal
application
 Booster is located between the brake
pedal linkage and the master cylinder
 When the driver presses on the brake
pedal, the brake booster helps push on
the master cylinder pistons

© Goodheart-Willcox Co., Inc.

 Vacuum Booster
 Uses vacuum produced in the engine
intake manifold or by a separate pump
to apply the hydraulic brake system
 Consists of a housing that encloses a
diaphragm
 When vacuum is applied to one side of
the booster, the diaphragm moves
toward the low-pressure area

© Goodheart-Willcox Co., Inc.

 Vacuum
Booster
Operation

© Goodheart-Willcox Co., Inc.

 Atmospheric
Suspended Brake
Booster
 Atmospheric pressure is present on
both sides of the diaphragm when the
brakes are released
 When the brakes are applied, vacuum
is routed to one side of the booster
 Atmospheric pressure then pushes on
and moves the diaphragm

© Goodheart-Willcox Co., Inc.

 Vacuum Suspended
Brake Booster
 Vacuum is present on both sides of the
diaphragm when the brakes are
released
 When the brakes are applied, vacuum
is released from one side of the
booster
 Atmospheric pressure then pushes on
and moves the diaphragm

© Goodheart-Willcox Co., Inc.

 Vacuum Brake Booster

© Goodheart-Willcox Co., Inc.

 Hydraulic Booster
 Uses power steering pump pressure to
help the driver apply the brake pedal
 Known as hydro-boost or hydra-
booster
 Commonly used on vehicles with diesel
engines
diesel engines do not produce a usable
amount of intake manifold vacuum

© Goodheart-Willcox Co., Inc.

 Hydraulic Booster

© Goodheart-Willcox Co., Inc.

 Hydraulic Booster

When the pedal pushes on the unit, the

spool valve allows more oil to enter the
pressure chamber, pushing on the
power piston
© Goodheart-Willcox Co., Inc.
 Brake Fluid
 Specially blended hydraulic fluid that
transfers pressure to the wheel brake
assemblies
 Rated by the SAE and DOT
 SAE (Society of Automotive Engineers)
 DOT (Department of Transportation)

© Goodheart-Willcox Co., Inc.

 Brake Fluid
 Brake fluid must have the following
characteristics:
correct viscosity at all temperatures
high boiling point
noncorrosive
water tolerant
lubricates components
low freezing point

© Goodheart-Willcox Co., Inc.

 Brake Lines and Hoses
 Transfer fluid pressure from the master
cylinder to the wheel brake assemblies
 Lines
made of double wall steel tubing
tubing ends use double flare or ISO flare
 Hoses
made of reinforced rubber
used where flexing action is necessary

© Goodheart-Willcox Co., Inc.

 Brake Lines and Hoses

© Goodheart-Willcox Co., Inc.

 Brake Line Hardware

Brackets and
clips secure the
hoses and lines
to prevent
damage

© Goodheart-Willcox Co., Inc.

 Brake
Systems

Often used on rear-

wheel-drive vehicles

Often used on front-

wheel-drive vehicles,
with high front to
rear brake ratio
© Goodheart-Willcox Co., Inc.
 Disc Brake Assembly

Assembly consists of a caliper, brake

pads, a rotor, and hardware
© Goodheart-Willcox Co., Inc.
 Single Piston Caliper

Caliper slides as the piston moves in to

clamp the brake pads against the rotor
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 Fixed Caliper

Caliper remains stationary as pistons on

each side clamp the rotor
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 Brake Caliper
Assembly

© Goodheart-Willcox Co., Inc.

 Caliper Components
 Piston seal
prevents fluid leakage between the piston
and the cylinder
helps pull the piston back into the cylinder
when the brakes are not applied
 Boot
prevents road dirt and water entry
 Bleeder screw
allows air to be removed from the system

© Goodheart-Willcox Co., Inc.

 Caliper Operation
 When the brakes are applied, brake
fluid flows into the caliper cylinder
 Fluid pressure pushes the piston
outward, forcing the brake pads into
the rotor
 When the brakes are released, the
stretched piston seal pulls the piston
back into the bore, as fluid pressure
drops

© Goodheart-Willcox Co., Inc.

 Caliper Operation

Brakes applied Brakes released

© Goodheart-Willcox Co., Inc.
 Disc Brake Pads
 Steel plates to which linings are riveted
 Linings
made of heat-resistant organic or
semimetallic friction material
semimetallic linings withstand higher
temperatures without losing their frictional
properties

© Goodheart-Willcox Co., Inc.

 Disc Brake Pads
 Anti-rattle clips
keep the brake pads from vibrating and
rattling
 Pad wear sensor
metal tab on the brake pad
emits a loud squeal when it scrapes
against the brake disc when the lining has
worn too thin

© Goodheart-Willcox Co., Inc.

 Brake Disc (Rotor)
 Uses friction from the brake pads to
slow or stop wheel rotation
 Normally made of cast iron
 Constructed as part of the hub, or a
separate unit
 May be solid, or a ventilated rib
construction

© Goodheart-Willcox Co., Inc.

 Disc Brake Assembly

This rotor is vented to increase cooling

© Goodheart-Willcox Co., Inc.
 Floating Caliper
 Disc brake is mounted on two bolts
supported by rubber bushings
 Uses one piston
 Caliper is free to shift, or float, in the
rubber bushings

© Goodheart-Willcox Co., Inc.

 Sliding Caliper
 Uses one piston
 Mounted in slots machined in the
caliper adapter
 Caliper is free to slide sideways in the
slots as the linings wear

© Goodheart-Willcox Co., Inc.

 Fixed Caliper
 Uses more than one piston and caliper
cylinder
 Caliper is bolted directly to the steering
knuckle
 Pistons on both sides of the disc push
against the brake pads

© Goodheart-Willcox Co., Inc.

 Drum Brake Assembly

Large drum surrounds the brake shoes

and the hydraulic wheel cylinder
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 Backing Plate
 Holds the springs, wheel cylinder, and
other parts inside the drum
 Helps keep road dirt and water off the
brakes
 Bolts to the axle housing or the spindle
support

© Goodheart-Willcox Co., Inc.

 Wheel Cylinder
Assembly

Uses master cylinder pressure to force

the brake shoes out against the drum
© Goodheart-Willcox Co., Inc.
 Wheel Cylinder
Components
 Boots
keep road dirt and water out of the
cylinder
 Pistons
metal or plastic plungers that transfer
force out of the cylinder to the brake
shoes
 Cups
rubber seals that keep fluid from leaking
past the pistons
© Goodheart-Willcox Co., Inc.
 Wheel Cylinder
Components
 Springs
hold the rubber cups against the pistons
when the wheel cylinder assembly is not
pressurized
metal expanders may be used on the
ends
 Bleeder screw
provides a means of removing air from
the brake system
© Goodheart-Willcox Co., Inc.
 Brake Shoes
 Rub against the revolving brake drum
to produce braking action
 Made by fastening organic friction
material onto a metal shoe
rivets or bonding agents may be used
 Primary shoe is the front shoe
uses the shortest lining
 Secondary shoe is the rear shoe
uses the largest lining surface area

© Goodheart-Willcox Co., Inc.

 Brake Shoes
 Retracting springs
pull the brake shoes away from the brake
drums when the brake pedal is released
 Hold-down springs
hold the brake shoes against the backing
plate when the brakes are in the released
position

© Goodheart-Willcox Co., Inc.

 Drum Brake Assembly

© Goodheart-Willcox Co., Inc.

 Brake Shoe Adjusters
 Maintain the correct drum-to-lining
clearance as the brake linings wear
 Automatic adjusters normally function
when the brakes are applied with the
vehicle moving in reverse
 If there is too much lining clearance,
the brake shoes move outward and
rotate with the drum enough to operate
the adjuster lever

© Goodheart-Willcox Co., Inc.

 Brake Shoe Adjusters

Cable-type star wheel adjuster

© Goodheart-Willcox Co., Inc.
 Brake Shoe Adjusters

Link-type star wheel adjuster

© Goodheart-Willcox Co., Inc.
 Brake Shoe Adjusters

Lever-type star wheel adjuster

© Goodheart-Willcox Co., Inc.
 Brake Shoe Adjusters

Cable-type star wheel adjuster with an

overtravel spring
© Goodheart-Willcox Co., Inc.
 Brake Shoe Adjusters

Lever-latch adjuster
© Goodheart-Willcox Co., Inc.
 Brake Shoe Adjusters

Sliding-latch adjuster
© Goodheart-Willcox Co., Inc.
 Brake Drums

Provide a rubbing surface for

the brake shoe linings
© Goodheart-Willcox Co., Inc.
 Brake Shoe
Energization
 When the brake shoes are forced
against the rotating drum, they are
pulled away from their pivot point by
friction
 This self-energizing action draws the
shoes tighter against the drum
 Servo action results when the primary
shoe helps apply the secondary shoe
© Goodheart-Willcox Co., Inc.
 Brake Shoe
Energization
Self-Energizing Action.
Primary shoe is self-
energized

Servo Action. Less wheel

cylinder hydraulic
pressure is needed to
apply the brakes
© Goodheart-Willcox Co., Inc.
 Control Valves and
Switches

© Goodheart-Willcox Co., Inc.

 Stop Light Switch
 Operates the rear brake lights
 Normally open switch, usually mounted
on the brake pedal mechanism
 When the brake pedal is pressed, it
closes the switch

© Goodheart-Willcox Co., Inc.

 Brake Warning Light
Switch
 Also called the pressure differential
valve
 Warns the driver of a pressure loss on
one side of a dual brake system
 If a leak develops in either the primary
or secondary brake system, unequal
pressure pushes the switch piston to
one side, grounding the indicator circuit

© Goodheart-Willcox Co., Inc.

 Brake Warning Light
Circuit

© Goodheart-Willcox Co., Inc.

 Brake Warning Light
Switch

Pressure difference pushes the piston to

close the warning lamp circuit
© Goodheart-Willcox Co., Inc.
 Low-Fluid Warning
Light Switch
 Turns on a dash light if the brake fluid
in the master cylinder becomes low
 Often mounts in the master cylinder lid
or cover
 Operated by a float

© Goodheart-Willcox Co., Inc.

 Metering Valve
 Used to equalize braking action on
vehicles with front-wheel disc brakes
and rear-wheel drum brakes
 Located in the line to the disc brakes
 Prevents the front brakes from applying
until pressure reaches approximately
75–135 psi (517–930 kPa)
 Overcomes rear brake return springs

© Goodheart-Willcox Co., Inc.

 Proportioning Valve
 Used to equalize braking action on
vehicles with front-wheel disc brakes
and rear-wheel drum brakes
 Located in the line to the drum brakes
 Limits pressure at the rear drum brakes
when high pressure is needed to apply
the front disc brakes
 Minimizes rear-wheel lockup during
heavy braking

© Goodheart-Willcox Co., Inc.

 Combination Valve

 Single unit that functions as a brake

warning light switch, a metering valve,
and/or a proportioning valve
 Common on late-model vehicles

© Goodheart-Willcox Co., Inc.

 Combination Valve

© Goodheart-Willcox Co., Inc.

 Master Cylinder

Incorporates a proportioning valve and a

warning light switch
© Goodheart-Willcox Co., Inc.
© Goodheart-Willcox Co., Inc.
 Parking Brake
Operation
 When the hand or foot lever is
activated, it pulls a steel cable that runs
through a housing
 Cable movement pulls on a lever inside
the drum or disc brake assembly,
forcing the brake linings against the
rear drums or discs

© Goodheart-Willcox Co., Inc.

 Parking
Brake
Components
Foot-operated
parking brake
pedal

Lever pushes the

shoes against the
drum
© Goodheart-Willcox Co., Inc.
 Parking Brake
Operation
(Rear Disc Brakes)
 A thrust screw and a lever can be
added to the brake caliper
 When the parking brake is applied, the
cable pulls on the caliper lever
 Caliper lever turns the thrust screw,
which pushes on the caliper piston and
applies the brake pads to the disc

© Goodheart-Willcox Co., Inc.

 Rear Disc Brake
Caliper

Note the parking brake mechanism

© Goodheart-Willcox Co., Inc.