start

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By James D. Halderman

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OBJECTIVES:
After studying Chapter 67, the reader should
be able to:

Prepare for ASE Brakes (A5) certification test.

List the parts and terms for disc and drum
brakes.
Describe brake design requirements.
List the six brake system categories.
Discuss federal braking and stopping
standards.

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

By James D. Halderman

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KEY TERMS:
adjustable pedals antilock braking system (ABS) apply
system
base brakes boost system brake balance control
system brake pedal brake warning lights
Department of Transportation (DOT) disc brakes drum
brakes
electric adjustable pedals (EAP)
Federal Motor Vehicle Safety Standards (FMVSS)
foundation brakes
Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition
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KEY TERMS:
gross vehicle weight rating (GVWR)
hydraulic system
lightly loaded vehicle weight (LLVW)
parking brake
red brake warning lamp
service brakes snub wheel brakes

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Brakes are by far the most important mechanism on

any vehicle because the safety and lives of those
riding in the vehicle depend on proper operation
of the braking system.
It has been estimated that the brakes on the average
vehicle are applied 50,000 times a year!

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

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HOW BRAKES STOP VEHICLES

Brakesareanenergyabsorbingmechanismthatconvertsvehicle
movementintoheatwhilestoppingtherotationofthewheels.
Allbrakingsystemsaredesignedtoreducethespeedandstopa
movingvehicleandtokeepitfrommovingifthevehicleis
stationary.
Servicebrakesarethemaindriveroperatedbrakesofthevehicle,
andarealsocalledbasebrakesorfoundationbrakes.
SeeFigure671.

Continued
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Figure 671 Typical vehicle brake system showing all typical components.

Continued
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Mostvehiclesbuiltsincethelate1920suseabrakeoneachwheel.
Tostopawheel,thedriverexertsaforceonabrakepedal.Forceon
thebrakepedalpressurizesbrakefluidinamastercylinder.
Thishydraulicforce(liquidunderpressure)istransferredthrough
steellinesandflexiblebrakelinestoawheelcylinderorcaliperat
eachwheel.Hydraulicpressuretoeachwheelcylinderorcaliperis
usedtoforcefrictionmaterialsagainstthebrakedrumorrotor.
Theheavierthevehicleandthehigherthespeed,themoreheatthe
brakeshavetobeabletoabsorb.Long,steephillscancausethe
brakestooverheat,reducingthefrictionnecessarytoslowandstopa
vehicle.
SeeFigures672and673.
Continued
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Figure 673 When driving down long,steep

grades, select a lower transmission gear to
allow the engine compression to help
maintain vehicle speed.

Figure 672 Brakes change the energy of

the moving vehicle into heat. Too much
heat and brakes fail, as indicated on this
sign coming down from Pikes Peak in
Colorado at 14,000 ft (4,300 m).

Continued
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DRUM BRAKES
Drumbrakesareusedontherearofmanyrearwheeldrive,
frontwheeldrive,andfourwheeldrivevehicles.
Whendrumbrakesareapplied,brakeshoesaremovedoutward
againstarotatingbrakedrum.Thewheelstudsforthewheelsare
attachedtothedrum.Whenthedrumslowsandstops,thewheels
alsoslowandstop.
Drumbrakesareeconomicaltomanufacture,service,andrepair.
Partsarereadilyavailableandreasonablypriced.Onsome
vehicles,anadditionaldrumbrakeisusedasaparkingbrakeon
vehiclesequippedwithreardiscbrakes.
SeeFigures674and675.
Continued
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Figure 674 Typical drum brake assembly.

Continued
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Figure 675 Drum brake assembly as used on the right rear wheel.

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DISC BRAKES
Discbrakesareusedonthefrontofmostvehiclesbuiltsincethe
early1970sandontherearwheelsofmanyvehicles.
Adiscbrakeoperatesby
squeezingbrakepadson
bothsidesofarotoror
discthatisattachedto
thewheel.
Figure 676
Typical disc brake assembly.

Duetothefrictionbetween
theroadsurfaceandthe
tires,thevehiclestops.
Continued
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BRAKE DESIGN REQUIREMENTS

Tosummarize,eventsnecessarytostopavehicleinclude:
1. Thedriverpressesonthebrakepedal.
2. Thebrakepedalforceistransferredhydraulicallytoawheel
cylinderorcaliperateachwheel.
3. Hydraulicpressureinsidethewheelcylinderorcaliperpresses
frictionmaterials(brakeshoesorpads)againstrotatingbrake
drumsorrotors.
4. Thefrictionslowsandstopsthedrumorrotor.Sincethedrum
orrotorisboltedtothewheelofthevehicle,thewheelalso
stops.
5. Whenthewheelsofthevehicleslowandstop,thetiresmust
havefriction(traction)withtheroadtostopthevehicle.
Continued
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Allbrakingforcesmustprovideforthefollowing:
1. Equalforcesmustbeappliedtoboththeleftandrightsidesof
thevehicletoassurestraightstops.
2. Hydraulicsystemsmustbeproperlyengineeredandserviced
toprovideforchangesasvehicleweightshiftsforwardduring
braking.
Hydraulicvalvesmustbeincorporatedintothehydraulic
systemtopermitthemaximumpossiblebrakingforcesbut
stillpreventundesirablewheellockup.
Antilockbrakingsystems(ABS)arespecificallydesignedto
preventwheellockupunderalldrivingconditions,including
wetoricyroadconditions.
Continued
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3. Thehydraulicsystemmustuseafluidthatwillnotevaporate
orfreeze.Thefluidhastowithstandextremetemperatures
withoutboilingandmustnotdamagerubberormetalpartsof
thebrakingsystem.
4. Thefrictionmaterial(brakingliningorbrakepads)mustbe
designedtoprovideadequatefrictionbetweenthestationary
axlesandtherotatingdrumorrotor.Thefrictionmaterial
shouldbeenvironmentallysafe.Nonasbestosliningis
consideredtobesafefortheenvironmentandthetechnician.
5. Thedesignofthebrakingsystemshouldsecurethebrake
liningsolidlytopreventthemovementofthefrictionmaterial
duringbraking.
Continued
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6.

Mostbrakingsystemsincorporateapowerassistunitthat
reducesdrivereffortbutdoesnotreducestoppingdistance.
Vacuumfromtheintakemanifoldisthemostcommonlyused
sourceofvacuumforpowerbrakeboosters.Theengineitself
mustbefunctioningcorrectlyforproperoperationofthe
powervacuumbooster.

NOTE: Itisthismovementofthefrictionmaterialthatcausesbrake

noise(squeal).Variousmovementdampersareusedbythevehicle
manufacturerstohelpcontrolanymovementthatdoesoccur.Itis
importantthateverytechnicianrestoretheoperationofallaspectsofthe
brakingsystemwhenevertheyareserviced,eventhenoisedampers.

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BRAKE SYSTEM CATEGORIES

Brakesystemcomponents
canbeclassifiedintosix
subsystemcategories,
dependingonfunction.

Figure 677
Typical brake system components.
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ApplySystemDriverstartsoperationofthesystembypressingthe
brakepedalorapplyingtheparkingbrake.Theapplysystem
includesalllevers,pedals,orlinkageneeded.
BoostSystemUsedonmostvehiclestoincreasebrakepedalforce.
HydraulicSystemBrakepedalforceistransferredtothehydraulic
system,whereforceisdirectedtothewheelbrakes.
WheelBrakesHydraulicpressuremovesapiston,inadiscor
drumbrakesystem,thatusesfrictiontopressmaterialagainsta
rotatingdrumorrotor.Resultingfrictionslowswheelrotation.

Continued
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BrakeBalanceControlSystemMechanical,electrical,and
hydrauliccomponentsensurebrakesareappliedquickly,with
balancedpressureforsafeoperation.Componentsinclude
meteringvalves,proportioningvalves,andantilockbraking
systemcomponents.
BrakeWarningLightsTheredbrakewarninglamplights
wheneverahydraulicsystemfailureoccurs.TheamberABS
warninglampordimredbrakelightindicatesanABSselftest
and/orapossibleproblemintheABSsystem.
SeeFigures679and6710.

Continued
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Figure 679 The red brake warning lamp alerts the driver to a possible brake system fault.

Figure 6710 The ABS dash warning lamp

alerts the driver to a possible antilock brake
system fault.

Continued
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How Do Adjustable Pedals Work?

Adjustable pedals, also called electric
adjustable pedals (EAP), place the brake
pedal and the accelerator pedal on
movable brackets that are motor operated.
A typical adjustable pedal system includes
the following components:
1. Adjustable pedal position switch
allows the driver to position the pedals.
2. Adjustable pedal assemblymotor,
threaded adjustment rods and a pedal
position sensor.
Pedal and seat system position is usually
included as part of memory seat function
and can be set for two or more drivers.
Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition
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Figure 678 A typical adjustable pedal

assembly. Both the accelerator and the
brake pedal can be moved forward and
rearward by using the adjustable pedal
position switch.
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ANTILOCK BRAKE SYSTEM OPERATION

Thepurposeofanantilockbrakingsystem(ABS)istoprevent
thewheelslockingduringbraking,especiallyonlowfriction
surfacessuchaswet,icy,orsnowyroads.
Itisthefrictionbetweenthetiretreadandtheroadthatdoesthe
actualstoppingofthevehicle.ABSdoesnotmeanavehiclecan
stopquicklyonallroadsurfaces.
Alockedwheelhaslesstractiontothe
roadsurfacethanarotatingwheel.
ABSusessensorsatthewheelstomeasurethewheelspeed.Ifa
wheelisrotatingslowerthantheothers,indicatingpossiblelockup
(forexample,onanicyspot),theABScomputerwillcontrolthe
brakefluidpressuretothatwheelforafractionofasecond.
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Ifawheelstartstolockup,thepurposeoftheABSsystemisto
pulsethebrakesonandofftomaintaindirectionalstabilitywith
maximumbrakingforce.
ManyABSunitscausethebrakepedaltopulseiftheunitis
workingintheABSmode,acauseforconcernforsomedrivers.
ThepulsingbrakepedalinformsthedriverthattheABSisbeing
activated.
SomeABSunitsuseanisolatorvalveintheABSunittoprevent
brakepedalpulsationsduringABSoperation.Withthesetypesof
systems,itisoftendifficultforthedrivertoknowifandwhenthe
ABSunitisworkingtocontrolalockingwheel.
SeeFigure6711foranoverviewofatypicalABSonarear
wheeldrivevehicle.

Continued

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Figure 6711
Typical components of an antilock braking system (ABS) used on a rear-wheel drive vehicle.

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FEDERAL BRAKE STANDARDS

Thestatutespertainingtoautomotivebrakesystemsarepartofthe
FederalMotorVehicleSafetyStandards(FMVSS)established
bytheUnitedStatesDepartmentofTransportation(DOT).
Severalstandardsapplytospecificcomponentswithinthebrake
system.
Theoverallserviceandparkingbrakesystemsaredealtwithin
FMVSS135,coveringbrakesystemsafetybyestablishing
specificbrakeperformancerequirements.
Itdoesnotdictatethedesignofthesystem,althoughsome
requirementsmaymakeoldertechnologiesimpracticalor
obsolete.
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Fourpartsofthebrakesystemarespecificallyregulated:
Fluidreservoirandlabeling
Dashboardwarninglights
Amethodofautomaticadjustment
Amechanicallyengaging,frictiontypeparkingbrakesystem
ThemajorityofFMVSS135consistsofacomprehensivetest
proceduredesignedtorevealanyweaknessinavehiclesbraking
system.Thetestisusedbymanufacturerstocertifythebraking
performanceofallnewvehiclesavailableforpublicpurchase.

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FMVSS135BrakeTestThetestprocedureconsistsofupto24
steps,dependingonvehicleconfigurationandbrakingsystem.
Theactualperformancetestsaremadewiththevehicleloadedto
boththemanufacturersspecifiedgrossvehicleweightrating
(GVWR)andthelightlyloadedvehicleweight(LLVW),with
certainappliedbrakeforces.
Therearepreciseinstructionsforeverystepofthetest,including
thenumberoftimesthetestsmustberepeated,thesequenceof
thetesting,andtheallowablestoppingdistancefortheparticular
typeofvehicle.
Somehighlightsofthetestingprocedurefollow.
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AdhesionUtilization(torquewheelmethod)Forvehicles
notequippedwithABS,thistestisperformedatLLVWand
GVWRtodetermineifthebrakesystemwillmakeadequate
useoftheroadsurfaceinstoppingthevehicle.
ColdEffectivenessThistestisperformedatbothGVWRand
LLVW,todetermineifthevehiclewillhavesufficientstopping
powerwhenthebrakeliningmaterialsarenotpreheatedby
previousstops.
HighSpeedEffectivenessThistestisperformedonlyon
vehiclescapableofexceeding78mph(125km/h)todetermine
ifthebrakesystemwillprovideadequatestoppingpowerfor
allloadingconditions.Theallowablestoppingdistanceis
calculatedfromthemaximumspeedthevehiclecanattain.

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StopswiththeEngineOffThistestisforvehiclesequipped
withbrakepowerassistunits.Thevehicle,loadedtoGVWR,
muststopwithin230ft(70m),fromaspeedof62mph(100
km/h).Thistestmustberepeatedsixtimes.
AntilockFunctionalFailureThistestensuresthatservice
brakeswillfunctioncorrectlyintheeventofanantilock
functionalfailure,andthebrakesystemwarningindicatoris
activatedwhenanABSelectricalfunctionfailureoccurs.
VariableBrakeProportioningSystemThistestisperformed
onvehiclesequippedwitheitheramechanicaloranelectrical
variableproportioningsystem.Itensuresthat,intheeventofa
failure,thevehiclecanstillcometoastopinanacceptable
distance.Ifthevehicleusesanelectricallyoperatedvariable
brakeproportioningsystem,thebrakewarningsystemmust
immediatelyalertthedriverofanyelectricalfunctionalfailure.
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HydraulicCircuitFailureThistestisperformedtoensure
thatthedriverwillbealertedviathebrakewarningsystem
indicatorthatafailurehasoccurred,andthatthevehiclecan
stillbestoppedinanacceptabledistance.
BrakePowerAssistUnitInoperativeThistestmakessure
theservicebrakecanstopthevehicleinanacceptabledistance
withthebrakepowerassistunitinaninoperativestate.Itis
performedonvehicleswithbrakepowerassistunitsturnedoff
orinoperative.
ParkingBrakeTheparkingbrakealonewillholdthevehicle
stationaryineithertheforwardorreversedirectionona20%
gradeforaperiodofatleast5minutes.

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HeatingSnubsThisprocedureheatsthebrakesystemby
makingaseriesof15stopsfromahighspeed.Asnubisa
controlledbrakeapplication.ThevehicleisloadedtoGVWR,
withrapidaccelerationbetweeneachstoptominimizecooling
thebrakes.
HotPerformanceAfterthebrakesystemhasbeenheatedbya
seriesofheatingsnubs,thehotperformancetestis
immediatelyperformed.ThevehicleisloadedtoGVWRand
twostopsaremade.Thestoppingdistancemustbewithin
acceptablelimitsasspecifiedinthetest.Thistestensuresthat
thebrakesystemonthevehiclewillnotfadefollowingaseries
ofhighspeedstopsatGVWR.

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Do the FMVSS 135 Standards Apply to Replacement

Brake Part Performance?
No. The Federal Motor Vehicle Safety Standard 135 applies to new vehicles.
Replacement parts used during a brake repair or replacement may or may
not permit the vehicle to achieve the same standards as when new. To help
ensure like-new braking performance, the service technician should always
use quality brake parts from a known manufacturer.

Althoughthesetestsmayseemextreme,rememberthattheyare
onlyaminimumstandardofperformance.
Anybrakerepairworkshouldalsoleavethebrakesystemcapable
ofmeetingFMVSS135.

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BRAKE REPAIR AND THE LAW

Onceanautomobileleavesthefactory,theresponsibilityfor
maintainingthedesignedinlevelofbrakingperformancefallson
theownerofthevehicle.Ownerslooktotrainedautomotive
technicianstoservicetheirbrakesystems.

Regardlessofspecificlawsgoverningbrakerepair,atechis
alwaysliablefordamageorinjuriesresultingfromrepairs
performedinanunprofessionalorunworkmanlikemanner.
Thereisonlyoneacceptablegoalwhenmakingbrakesystem
repairs:torestorethesystemanditscomponentpartssothey
performtooriginalspecifications.
Thepurposeofanyrepairisto
restorelikenewperformance.
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SUMMARY
1. Drumbrakesareusedontherearofmostvehicles.
2. Discbrakesareusedonthefrontofmostvehicles.
Thesixbrakesubsystemsinclude:applysystem,boostsystem,
hydraulicsystem,wheelbrakes,brakebalancecontrolsystem
(whichincludesABS),andbrakewarninglights.
3. Anantilockbrakingsystem(ABS)pulsesthehydraulicforceto
thewheelstopreventthetiresfromlockingup.Alockedtire
haslowerfrictionthanarollingtire.

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UpperSaddle
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River,NJ
NJ07458
07458

SUMMARY

(cont.)

4. ThefederalbrakestandardscoveredinFMVSS135regulate
specificbrakeperformancerequirements,butnottheactual
designofthebrakingsystem.

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition

By James D. Halderman

2008
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
Pearson
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458

end
Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition
By James D. Halderman

2008
2009Pearson
PearsonEducation,
Education,Inc.
Inc.
Pearson
PearsonPrentice
PrenticeHall
Hall- -Upper
UpperSaddle
SaddleRiver,
River,NJ
NJ07458
07458