MAINTENEANCE AND REPAIR OF

HYDRAULIC BRAKE SYSTEMS

TOPIC 7
 OBJECTIVES
• Explain the theory of the hydraulic brake
system
• Explain the functioning of and operation of
the hydraulic brake system
• Perform basic maintenance on the brake
system
• Diagnose and repair various parts of the brake
system
 SO Explain the theory of the hydraulic brake system
7.1
Concept of friction.
 Automotive brakes are designed to slow and
stop a vehicle by transforming kinetic energy
(motion energy) into heat energy.
 This is accomplished using friction between
the lining material on non-moving brake disc
pads and brake shoes.
 BRAKE SYSTEM
Question 1.
On application the brakes lock. This action is
known as:
a) Static friction.
b) Kinetic friction.
 SO Explain the theory of the hydraulic brake system. Continue
7.1
Pascal's Law:
 First, liquids is incompressible.
 Secondly, when pressure is applied to a liquid
within a closed space, pressure is exerted
equally in all directions.
Pascal’s Laws
 SO Explain the fundamentals law of the hydraulic brake system
7.1.1
Pascal's Law:
 First, liquids is incompressible.
 Secondly, when pressure is applied to a liquid
within a closed space, pressure is exerted
equally in all directions.
 BRAKE SYSTEM
Question 2.
What is the main purpose of a brake system?

a) To stop the vehicle when you want it to stop

b) Stop the vehicle during emergencies
c) Stop the vehicle safe and in a straight line.
 SO The characteristics of brake fluid
7.1.2
Brake fluid should:
Remain free flowing at all temperatures
 Have a high boiling point
 Non-corrosive to internal metal components
 Water tolerant (Hygroscopic)
 Lubricant to internal brake components
 Low freezing point
 BRAKE SYSTEM
Question 3.

Any fluid is acceptable to use in the brake

system.

True or False
 SO
The operation of the hydraulic brake system
7.1.3
• Brake pedal pushed down,
• The rod from the brake pedal pushes on the
piston.
• The piston moves forward in the cylinder and
forced fluid into the brake lines.
• The force that the piston exerts on the fluid is
transferred to the wheel brake cylinder
• The brake shoes and disc pads are forced
against the brake drums and discs.
 SO
The operation of the hydraulic brake system
7.1.3
Brake action.

Click on link for video

 SO The functioning and operation of the
7.2 hydraulic brake system

Types of brakes on cars:

Drum brakes
Disc brakes
 SO Explain the functioning of and operating
7.2.1 principles of the hydraulic brake system

Drum brakes
Rear or front of
vehicle

Components:
 Wheel cylinder
 Brake shoes
 Brake drum
 SO Explain the functioning of and operating
7.2.1 principles of the hydraulic brake system

Drum brakes
 Wheel cylinder
• hydraulic pressure from the
master cylinder moves to the
wheel cylinder pistons outward.
• The cylinders pistons forces the
brake shoes against the drum.
 BRAKE SYSTEM
Question 4.
If a vehicle has both disc and drum brakes, the
disc brakes must be fitted to the front wheels. Is
this true or false?
True or False
 SO Explain the functioning of and operating
7.2.1 principles of the hydraulic brake system

Drum brakes
 Brake shoes
• Friction material that
press against the brake
drum.
 SO Explain the functioning of and operating
7.2.1 principles of the hydraulic brake system

Drum brakes
 Brake drum
• The friction surface
for the brake shoes.
 BRAKE SYSTEM
Question 5.
In brake systems friction material(brake Linings)
are the only friction material involved in the
brake action.

True or False
 SO Explain the functioning of and operating
7.2.1 principles of the hydraulic brake system

Disc brakes
Rear and front
of vehicle.

Components:
 Caliper
 Caliper cylinder
 Brake pads
 Disc
 BRAKE SYSTEM
Question 6.
Why would a disc brake be ventilated?

a) To reduce weight
b) To increase heating
c) To reduce momentum
d) To ensure constant cooling.
 SO Explain the functioning of and operating
7.2.1 principles of the hydraulic brake system

Brake Caliper:
 Create clamping
force for disc
pads.
 SO Explain the functioning of and operating
7.2.1 principles of the hydraulic brake system

Brake Disc:
 Friction surface
for disc pads.
 SO Explain the functioning of and operating
7.2.1 principles of the hydraulic brake system

Brake pads:
 Friction material
for disc brakes.
 SO Explain the functioning of and operating
7.2.1 principles of the hydraulic brake system

Park brake:
 Hold vehicle
when stationary.
 CHARGING SYSTEM
Question 7.
Force is transferred from the handbrake handle
to the wheels by?
a) Rod link
b) Cable
c) Brake fluid
 SO Explain the functioning of and operating
7.2.1 principles of the hydraulic brake system

Brake booster:
 Increase the
force applied
by the brake
pedal.
 CHARGING SYSTEM
Question 8.
A vacuum brake booster uses;
a) hydraulic pressure
b) pedal force or
c) engine vacuum to apply the hydraulic brake
system?
 SO Explain manual and pressure bleeding of
7.2.2 the hydraulic brake system

Manual:
Steps.
1. Attach tube to bleeder screw
2. Place other end of tube in
a container with clean brake fluid
3. Push brake pedal down
4. Open bleeder screw
5. Observe air bubbles to move out
6. Close breeder screw
7. Release brake pedal
8. Repeat process until no more air bubbles are visible.
Click link for video
 SO Explain manual and pressure bleeding of
7.2.2 the hydraulic brake system

Pressure bleeding:
1. Fill bleeder tank with clean brake
fluid
2. Supply air to bleeder tank
3. Remove brake master cylinder cap
4. Connect tank adapter to master
cylinder
5. Open bleeder tank to pressurise mast
cylinder
6. Connect tube to wheel cylinder bleeder screw
7. Place other end of tube in a container with clean brake fluid
8.Open bleeder screw
9.Brake fluid will flow into container
10. Close bleeder screw once system is free of air bubbles
11. Repeat at all wheels
 SO Safety procedures when working on the
7.2.2 brake system

Safety procedures:
 Prevent asbestos inhalation
 Safely lift the vehicle
 Wear safety glasses
 Brake fluid is hazardous
 Store brake fluid in sealed containers
 Keep brake fluid away from paintwork
 Discard brake fluid as a hazardous waste.
 BRAKE SYSTEM
Question 9.
Asbestosis is caused by inhaling dust from
brakes during normal maintenance. This sickness
invests in?
a) The eyes
b) The liver
c) The lungs
d) The heart
SO Perform basic maintenance on the brake system
7.3
 SO Check the brake system
7.3.1
• Check brake fluid level.
• Check for brake fluid leaks.
• Repair all brake related problems.
• Inspect brake lining thickness.
• Inspect brake drum and brake disc for condition
and cracks.
• Adjust brakes.
• Adjust hand brake.
• Replace brake fluid once every two years.
 BRAKE SYSTEM
Question 10.
How is the distance between the brake shoe and
brake drum adjusted?
a) By tightening the back plate
b) Adjusting the hold down springs
c) Adjusting the brake adjuster mechanism
d) Shortening the retraction springs
 SO Replace damaged or worn parts of the brake system
7.3.2
 Replace brake shoes
Replace disc brake pads
Clink link for video
Inspect brake light switch
 CHARGING SYSTEM
Question 11.
All of these would cause a low brake pedal,
EXCEPT:
Brake adjustment
Loose wheel bearing
Low brake fluid
Seized calliper piston
 SO Possible faults on the hydraulic brake system
7.3.3
Diagnosing the following brake problems:

 No brakes
 Hard pedal
 Brakes grab
 Brakes pull to one side
 Brake shudder
 Low pedal
 Dragging brakes
 Brake squeal
Click link for video
 BRAKE SYSTEM
Question 12.
A spongy brake pedal on a vehicle with 4-wheel
disc brakes with a longer than normal travel
indicates which of the following?
Air in the hydraulic system
Caliper piston seized
Parking brake out of adjustment
A faulty power booster
 SO
Checking the brake pressure controller
7.3.4
Reduce the risk of the rear brakes locking up.
limiting the hydraulic pressure
Click link for video
 SO
Checking drum and disc thickness
7.3.5
How to use a brake drum
micrometer
Click to link

How to measure a brake

disc

Click to link
 BRAKE SYSTEM
Question 13.
Replacing worn brake components ensure?
a) Regularly maintenance
b) Les brake noise
c) Improve vehicle safety
d) Improve stopping power.
 SO
7.3.6 Refill the brake fluid reservoir

SAFETY FIRST.
Wear PPE
Do not spill brake fluid on
paint work
Click link for video
 BRAKE SYSTEM
Question 14.
Brake fluid is skin and paint friendly.

True or False
 SO
Adjusting the park brake
7.3.7

Click on link
How to adjust a park brake.
 BRAKE SYSTEM
Question 15.
The function of the park brake is:
a) To stop the vehicle safely.
b) To use as an emergency brake.
c) To hold the vehicle while stationary.
d) A security system.
 SO Diagnose and repair components of the
7.4 brake system
Repairs to:
• Wheel brake cylinder
• Brake caliper
• Brake hoses/lines
• Brake master cylinder

• Click on link for video.???????????

 CHARGING SYSTEM
Question 16.
Maintenance of the brake system is important.
a) To safe money.
b) To extend the service life of the vehicle.
c) To ensure vehicle and passenger safety.
d) To safe on car insurance.
 SUMMARY
You gained an understanding of the:
 Function of the brake system.
Operation of the brake system.
Types of brake assemblies.
Maintenance of the brake system.
Diagnosing of the brake system.