AUTO-1450: Automotive Braking Systems           1

AUTO-1450: AUTOMOTIVE BRAKING SYSTEMSCuyahoga Community CollegeViewing: AUTO-1450 : Automotive Braking SystemsBoard of Trustees:2017-03-30

Academic Term:2017-08-24

Subject CodeAUTO - Automotive Technology

Course Number:1450

Title:Automotive Braking Systems

Catalog Description:Designed to provide student with foundation in theory and operation ofautomotive braking systems. Includes hydraulic brake principles, machiningoperations, and troubleshooting and repair of disc and drum brake assemblies.Operation and diagnosis of anti-lock braking systems included.

Credit Hour(s):3

Lecture Hour(s):2Lab Hour(s):3

Other Hour(s):0

RequisitesPrerequisite and CorequisiteNone.

I. ACADEMIC CREDITAcademic Credit According to the Ohio Department of Higher Education, one (1) semester hour of college credit will be awardedfor each lecture hour. Students will be expected to work on out-of-class assignments on a regular basis which, over the length ofthe course, would normally average two hours of out-of-class study for each hour of formal class activity. For laboratory hours, one(1) credit shall be awarded for a minimum of three laboratory hours in a standard week for which little or no out-of-class study isrequired since three hours will be in the lab (i.e. Laboratory 03 hours). Whereas, one (1) credit shall be awarded for a minimum oftwo laboratory hours in a standard week, if supplemented by out-of-class assignments which would normally average one hour ofout-of class study preparing for or following up the laboratory experience (i.e. Laboratory 02 hours). Credit is also awarded for otherhours such as directed practice, practicum, cooperative work experience, and field experience. The number of hours required toreceive credit is listed under Other Hours on the syllabus. The number of credit hours for lecture, lab and other hours are listed atthe beginning of the syllabus. Make sure you can prioritize your time accordingly. Proper planning, prioritization and dedication willenhance your success in this course.The standard expectation for an online course is that you will spend 3 hours per week for each credit hour.

II. ACCESSIBILITY STATEMENTIf you need any special course adaptations or accommodations because of a documented disability, please notify your instructorwithin a reasonable length of time, preferably the first week of the term with formal notice of that need (i.e. an official letter from theStudent Accessibility Services (SAS) office). Accommodations will not be made retroactively.

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For specific information pertaining to ADA accommodation, please contact your campus SAS office or visit online at https://www.tri-c.edu/student-accessibility-services (https://www.tri-c.edu/student-accessibility-services/). Blackboard accessibility information isavailable at http://access.blackboard.com.Eastern (216) 987-2052 - Voice. (216) 987-2423 - FaxMetropolitan (216) 987-4344 – Voice.(216) 987-3257 - Fax.Western (216) 987-5079 – Voice. (216) 987-5118 - Fax.Westshore (216) 987-3900 – Voice. (216) 987-5294 - Fax.Brunswick (216) 987-5079 – Voice. (216) 987-5118 - Fax.Off-Site (216) 987-5079 – Voice

III. ATTENDANCE TRACKINGRegular class attendance is expected. Tri-C is required by law to verify the enrollment of students who participate in federal Title IVstudent aid programs and/or who receive educational benefits through other funding sources. Eligibility for federal student financialaid is based in part on enrollment status.Students who do not attend classes for the entire term are required to withdraw from the course(s). Additionally, students whowithdraw from a course or stop attending class without officially withdrawing may be required to return all or a portion of theirfinancial aid based on the date of last attendance. Students who do not attend the full session are responsible for withdrawing fromthe course(s).Tri-C is responsible for identifying students who have not attended a course before financial aid funds can be applied to students’accounts.Therefore, attendance is recorded in the following ways:• For in-person and blended-learning courses, students are required to attend the course by the 15th day of the semester (orequivalent for terms shorter than five weeks) to be considered attending. Students who have not met all attendance requirements forin-person and blended courses, as described herein, within the first two weeks or equivalent, will be considered not attending.• For online courses, students are required to login at least two times per week and submit one assignment per week for the first twoweeks of the semester, or equivalent to the 15th day of the term. Students who have not met all attendance requirements for onlinecourses, as described herein, within the first two weeks or equivalent, will be considered not attending.At the conclusion of the first two weeks of a semester or equivalent, instructors report any registered students who have “NeverAttended” a course. Those students will be administratively withdrawn from that course. However, after the time period inthe previous paragraphs, if a student stops attending a class or wants or needs to withdraw, for any reason, it is the student’sresponsibility to take action to withdraw from the course. Students must complete and submit the appropriate Tri-C form by theestablished withdrawal deadline.Tri-C is required to ensure that students receive financial aid only for courses that they attend and complete. Students reported for notattending at least one of their registered courses will have all financial aid funds held until confirmation of attendance in registeredcourses has been verified. Students who fail to complete at least one course may be required to repay all or a portion of their federalfinancial aid funds and may be ineligible to receive future federal financial aid awards. Students who withdraw from classes prior tocompleting more than 60 percent of their enrolled class time may be subject to the required federal refund policy.If illness or emergency should necessitate a brief absence from class, students should confer with instructors upon their return.Students having problems with coursework due to a prolonged absence should confer with the instructor or a counselor.

IV. LEARNING OUTCOMES ASSESSMENTOccasionally, in addition to submitting assignments to their instructors for evaluation and a grade, students will also be asked tosubmit completed assignments, called ‘artifacts,’ for assessment of course and program outcomes and the College’s EssentialLearning Outcomes (ELOs). The artifacts will be submitted in Blackboard or a similar technology. The level of mastery of the outcomedemonstrated by the artifact DOES NOT affect the student’s grade or academic record in any way. However, some instructors requirethat students submit their artifact before receiving their final grade. Some artifacts will be randomly selected for assessment, whichwill help determine improvements and support needed to further student success. If you have any questions, please feel free to speakwith your instructor or contact the Learning Outcomes Assessment office.

V. CONCEALED CARRY STATEMENTCollege policy prohibits the possession of weapons on college property by students, faculty and staff, unless specifically approved inadvance as a job-related requirement (i.e., Tri-C campus police officers) or, in accordance with Ohio law, secured in a parked vehicle ina designated parking area only by an individual in possession of a valid conceal carry permit.As a Tri-C student, your behavior on campus must comply with the student code of conduct which is available on page 29 withinthe Tri-C student handbook, available at http://www.tri-c.edu/student-resources/documents/studenthandbook.pdf You must alsocomply with the College’s Zero Tolerance for Violence on College Property available at http://www.tri-c.edu/policies-and-procedures/documents/3354-1-20-10-zero-tolerance-for-violence-policy.pdf

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VI. CORONAVIRUS/COVID-19 STATEMENTStudents are responsible for adhering to all College health and safety guidance, including that which relates to the COVID-19pandemic.Public health requirements and standards are changing rapidly, and the College is adapting its guidance accordingly. Please checkyour Tri-C email and visit tri-c.edu/coronavirus regularly for updates.All students must adhere to the following general guidelines, until further notice:• Remain at home. Do not attend any in-person class or gathering.• Notify your instructor(s) if you are ill, have tested positive for COVID-19, or have been exposed to an individual who has testedpositive for COVID-19.• Wear a mask or face covering at all times, including, but not limited to: upon entering and exiting any Tri-C facility, in class, and in allcommon areas.• Maintain a distance of at least six feet between yourself and others at all times.• Provide the College with relevant information about your current health status and participate in any required on-site checks (e.g.,temperature checks).• Use only designated areas of Tri-C facilities, including entrances and exits. Sign in and out of Tri-C facilities as directed.The general guidelines listed above do not encompass all coronavirus-related guidance. These guidelines are subject to change atthe discretion of the College and under the direction of public health authorities. Students who fail to adhere to this guidance may besubject to disciplinary action under the College’s Student Code of Conduct and the Student Judicial Code.

OutcomesCourse Outcome(s):Diagnose brake systems.

Essential Learning Outcome Mapping:Not Applicable: No Essential Learning Outcomes mapped. This course does not require application-level assignments thatdemonstrate mastery in any of the Essential Learning Outcomes.

Objective(s):1. Identify and interpret brake system concerns; determine necessary action.2. Research applicable vehicle and service information, vehicle service history, service precautions, and technical service bulletins.3. Describe procedure for performing a road test to check brake system operation; including an anti-lock brake system (ABS).4. Install wheel and torque lug nuts.

Course Outcome(s):Diagnose and repair hydraulic brake systems.

Objective(s):1. Diagnose poor stopping, pulling or dragging concerns caused by malfunctions in the hydraulic system; determine necessary action.2. Inspect brake lines, flexible hoses, and fittings for leaks, dents, kinks, rust, cracks, bulging, and wear; check for loose fittings andsupports; determine necessary action.3. Replace brake lines, hoses, fittings, and supports.4. Fabricate brake lines using proper material and flaring procedures (double flare and ISO types).5. Select, handle, store, and fill brake fluids to proper level.6. Inspect, test, and/or replace components of brake warning light system.7. Identify components of brake warning light system.8. Bleed and/or flush brake system.9. Test brake fluid for contamination.10. Diagnose pressure concerns in the brake system using hydraulic principles (Pascal’s Law).11. Measure brake pedal height, travel, and free play (as applicable); determine necessary action.12. Check master cylinder for internal/external leaks and proper operation; determine necessary action.13. Remove, bench bleed, and reinstall master cylinder.

Course Outcome(s):Diagnose and repair drum brakes.

Objective(s):1. Diagnose poor stopping, noise, vibration, pulling, grabbing, dragging or pedal pulsation concerns; determine necessary action.2. Remove, clean, inspect, and measure brake drum diameter; determine necessary action.3. Refinish brake drum and measure final drum diameter; compare with specifications.4. Remove, clean, and inspect brake shoes, springs, pins, clips, levers, adjusters/self-adjusters, other related brake hardware, andbacking support plates; lubricate and reassemble.5. Inspect wheel cylinders for leaks and proper operation; remove and replace as needed.

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6. Pre-adjust brake shoes and parking brake; install brake drums or drum/hub assemblies and wheel bearings; perform final checksand adjustments.

Course Outcome(s):Diagnose and repair disc brakes.

Objective(s):1. Diagnose poor stopping, noise, vibration, pulling, grabbing, dragging, or pulsation concerns; determine necessary action.2. Remove and clean caliper assembly; inspect for leaks and damage/wear to caliper housing; determine necessary action.3. Clean and inspect caliper mounting and slides/pins for proper operation, wear, and damage; determine necessary action.4. Remove, inspect, and replace pads and retaining hardware; determine necessary action.5. Lubricate and reinstall caliper, pads, and related hardware; seat pads and inspect for leaks.6. Clean and inspect rotor; measure rotor thickness, thickness variation, and lateral runout; determine necessary action.7. Remove and reinstall rotor.8. Refinish rotor on vehicle; measure final rotor thickness and compare with specifications.9. Refinish rotor off vehicle; measure final rotor thickness and compare with specifications.10. Retract and re-adjust caliper piston on an integrated parking brake system.11. Check brake pad wear indicator; determine necessary action.12. Describe importance of operating vehicle to burnish/break-in replacement brake pads according to manufacturer’srecommendations.

Course Outcome(s):Diagnose and repair power-assisted brake systems.

Objective(s):1. Check brake pedal travel with, and without, engine running to verify proper power booster operation.2. Check vacuum supply (manifold or auxiliary pump) to vacuum-type power booster.3. Inspect vacuum-type power booster unit for leaks; inspect the check-valve for proper operation; determine necessary action.4. Inspect and test hydraulically-assisted power brake system for leaks and proper operation; determine necessary action.5. Measure and adjust master cylinder pushrod length.

Course Outcome(s):Diagnose and repair miscellaneous related brake components and systems (wheel bearings, parking brakes, electrical components).

Objective(s):1. Diagnose wheel bearing noises, wheel shimmy, and vibration concerns; determine necessary action.2. Remove, clean, inspect, repack, and install wheel bearings; replace seals; install hub and adjust bearings.3. Check parking brake cables and components for wear, binding, and corrosion; clean, lubricate, adjust or replace as needed.4. Check parking brake operation and parking brake indicator light system operation; determine necessary action.5. Check operation of brake stop light system.6. Replace wheel bearing and race.7. Remove and reinstall sealed wheel bearing assembly.

Course Outcome(s):Diagnose and repair electronic brake, traction and stability control components, and systems.

Objective(s):1. Identify and inspect electronic brake control system components; determine necessary action.2. Identify traction control/vehicle stability control system components.3. Describe the operation of a regenerative braking system.4. Diagnose poor stopping, wheel lock-up, abnormal pedal feel, unwanted application, and noise concerns associated with theelectronic brake control system; determine necessary action.5. Diagnose electronic brake control system electronic control(s) and components by retrieving diagnostic trouble codes, and/orusing recommended test equipment; determine necessary action.6. Depressurize high-pressure components of an electronic brake control system.7. Bleed the electronic brake control system hydraulic circuits.8. Test, diagnose, and service electronic brake control system speed sensors (digital and analog), toothed ring (tone wheel), andcircuits using a graphing multimeter (GMM)/digital storage oscilloscope (DSO) (includes output signal, resistance, shorts to voltage/ground, and frequency data).9. Diagnose electronic brake control system braking concerns caused by vehicle modifications (tire size, curb height, final drive ratio,etc.).10. Research applicable vehicle and service information, vehicle service history, service precautions, and technical service bulletins.

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11. Demonstrate knowledge of electrical/electronic series, parallel, and series-parallel circuits using principles of electricity (Ohm’sLaw).12. Demonstrate proper use of a digital multimeter (DMM) when measuring source voltage, voltage drop (including grounds), currentflow and resistance.13. Demonstrate knowledge of the causes and effects from shorts, grounds, opens, and resistance problems in electrical/electroniccircuits.14. Check operation of electrical circuits with a test light.15. Check operation of electrical circuits with fused jumper wires.16. Use wiring diagrams during the diagnosis (troubleshooting) of electrical/electronic circuit problems.17. Diagnose the cause(s) of excessive key-off battery drain (parasitic draw); determine necessary action.18. Inspect and test fusible links, circuit breakers, and fuses; determine necessary action.19. Inspect and test switches, connectors, relays, solenoid solid state devices, and wires of electrical/electronic circuits; determinenecessary action.20. Replace electrical connectors and terminal ends21. Repair wiring harness.22. Perform solder repair of electrical wiring.23. Check electrical/electronic circuit waveforms; interpret readings and determine needed repairs.24. Repair CAN/BUS wiring harness.

Course Outcome(s):Shop and personal safety is a primary and ongoing concern while in the repair environment for automotive braking systems; includingusing tools and equipment, working around supplemental restraint(SRS) or high voltage circuits, wearing personal protectionequipment, awareness of personal clothing, adornments and body, and knowledge of fire safety and evacuation routes.

Objective(s):1. For every outcome and/or supporting objective in AUTO-1450 Automotive Braking Systems the following safety requirements mustbe strictly enforced: Comply with personal and environmental safety practices associated with clothing; eye protection; hand tools;power equipment; proper ventilation; and the handling, storage, and disposal of chemicals/materials in accordance with local, state,and federal safety and environmental regulations.

Methods of Evaluation:1. Participation and discussion2. Observation3. Written assignments4. Exams5. Quizzes6. Lab tasks7. Classroom recitations

Course Content Outline:• Early brake designs• Automotive brake designs

a. External contracting-band brakesb. Internal expanding-band brakesc. Internal expanding-shoe brakesd. Disc brakes

• Brake system operation• Service brakes

a. Pedal assemblyb. Power boosterc. Master cylinderd. Hydraulic lines and hosese. Hydraulic switches and valve

• Wheel friction assembliesa. Drum brakesb. Disc brakes

• Parking brakesa. Parking brake friction assemblies

• Methods of brake actuation

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a. Mechanical actuationb. Hydraulic actuationc. Pneumatic actuationd. Electric actuation

• Brakes and the law• Federal brake standards

a. FMVSS 105 brake test• Brake repair and the law• Brakes and health• Asbestos exposure

a. Sources of asbestos exposureb. Effects of asbestos exposure

i. asbestosisii. cancer

• Asbestos precautions• Asbestos waste disposal• Chemical poisoning

a. Sources of chemical poisoningb. Effects of chemical poisoning

• Chemical precautions• Health care rights• Energy principles• Kinetic energy

a. Weight and speed effectsb. Kinetic energy and brake design

• Inertiaa. Weight transfer and bias

• Mechanical principles• Hydraulic principles

a. Non-compressibility of liquidsb. Constancy of pressurec. Hydraulic pressure and piston sized. Application force and piston sizee. Piston size versus piston travelf. Hydraulic principles and brake design

• Friction principlesa. Coefficient of friction

i. surface finish effectsii. friction material effects

iii. heat effectsb. Friction contact areac. Static and kinetic friction

• Friction and heata. Brake fade

• Brake fluid• Brake fluid specifications

a. Boiling pointb. Dry and wet boiling pointsc. Temperature compatibilityd. Mechanical compatibilitye. Fluid compatibility

• Brake fluid typesa. Polyglycol brake fluidb. Silicone brake fluidc. Hydraulic system mineral oil (HMSO)

• Brake fluid storage and handling• Brake bleeding

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a. Manual bleedingb. Pressure bleedingc. Vacuum bleeding

• Brake fluid changesa. Silicone brake fluid changes

• Brake linesa. Brake tubingb. Brake hoses

• Brake line fittings• Compression fittings

a. flare fittingsi. SAE flare fittings

ii. ISO flare fittings• Brake line routing• Pedal assemblies

a. Frame-mounted brake pedalsb. Suspended brake pedalsc. Brake pedal ratiod. Brake pedal freeplay

i. freeplay adjustment• Master cylinder construction

a. Brake fluid reserviori. reservoir covers

b. Master cylinder bodyc. Master cylinder pistonsd. Piston seals

• Master cylinder operation• Single piston master cylinder

a. Brakes not appliedb. Brake applicationc. Brake released. Brake pumping

• Dual-circuit brake systems• Standard dual-piston master cylinder

a. Brakes not appliedb. Brake application

i. primary circuit failureii. secondary circuit failure

c. Brake release and brake pumping• Quick-take-up master cylinder

a. Brakes not appliedb. Brake applicationc. Brake release

• Hydraulic valves• Residual pressure check valve

a. Residual check valve operationb. Systems without residual check valves

• Metering valvea. Metering valve operationb. Systems without metering valveesc. Metering valves and brake bleeding

• Proportioning valvea. Proportioning valve operationb. Height-sensing proportioning valve

• Combination valves• Brake system switches

a. Pressure differential switchb. Pressure differential switch operation

• Fluid level switch

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• Stoplight switch• Wheel cylinders

a. Wheel cylinder bodyb. Wheel cylinder pistons and seals

i. cup expandersc. Wheel cylinder dust bootsd. Wheel cylinder designse. Wheel cylinder operation

• Brake calipersa. Brake caliper body

i. piston bores1. brake fluid routing

b. Brake caliper pistonsi. piston heat transfer

c. Caliper piston materialsi. aluminum pistons

ii. cast iron and steel pistonsiii. phenolic pistons

d. Caliper piston sealsi. stroking piston seals

ii. fixed piston seals1. seal flex and piston retraction

iii. low drag caliper sealse. Brake caliper dust bootsf. Brake caliper operation

• Drum brake advantagesa. Self-energizing and servo actionb. Parking brake service

• Drum brake disadvantagesa. Brake fade

i. mechanical fadeii. lining fade

iii. gas fadeiv. water fade

b. Adjusting mechanismc. Brake pull

• Drum brake constructiona. Backing plate

i. shoe anchorsii. piston stops

iii. shoe contact padsiv. wheel cylinders

b. Brake shoesc. Brake shoe return springsd. Brake shoe holddownse. Parking brake linkagef. Brake drum

• Drum brake designa. Non-servo brakes

i. self energizing actionii. specific non servo brakes

iii. double trailing brakeiv. leading trailing brakev. double leading brake

vi. non-directionalb. Dual-servo brakes

i. dual-servo brake construction1. adjusting link2. Primary and secondary brake shoes

ii. dual-servo brake operation

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1. servo actioniii. other dual-servo brakes

c. Uni-servo braked. Brake adjusters

i. manual brake adjusters1. starwheel manual adjusters2. cam manual adjusters3. wedge manual adjuster4. anchor manual adjusters

ii. automatic brake adjusters1. servo brake starwheel automatic adjusters2. non-servo starwheel automatic adjusters3. lever-latch automatic adjuster4. strut-rod automatic adjusters5. strut quadrant automatic adjuster

• Disc brake advantagesa. Fade resistance

i. swept areaii. mechanical fade

iii. lining fadeiv. gas fadev. water fade

b. Self-adjusting abilityc. Freedom from pull

• Disc brake disadvantagesa. No self-energizing or servo actionb. Brake noisec. Poor parking brake performance

• Disc brake constructiona. Caliperb. Splash shieldc. Brake padsd. Brake rotor

• Disc brake designa. Fixed caliper design

i. fixed caliper advantagesii. fixed caliper disadvantages

b. Floating and sliding caliper designi. floating and sliding caliper advantages

ii. floating and sliding caliper disadvantagesc. Rear disc brakes

i. rear disc parking brakesii. four-wheel-disc hydraulic systems

d. Inboard disc brakes• Drum brake shoe construction

a. Primary and secondary brake shoes• Disc brake pad construction

a. Pad wear indicators• Shoe and pad friction materials

a. Organic brake liningsi. high temperature organic linings

ii. ’autobahn formula’ organic liningsb. Metallic brake liningsc. Semi-metallic brake linings

i. semi-metallic brake linings and rotor wearii. semi-metallic lining applications

d. Synthetic brake linings

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i. fiberglass brake liningsii. aramid brake linings

iii. ceramic brake liningse. Lining material coefficient of friction

i. edgebrandingii. hard and soft brake linings

f. Lining assembly methodsi. riveting

ii. bondingiii. mold bondingiv. fusing and brazing

g. Brake shoe to drum fiti. brake shoe arcing

1. cam grinding2. undersize grinding3. fixed anchor grinding

ii. shoe arcing and modern brake service• Brake drum and rotor construction

a. Solid drumsb. Composite drumsc. Steel and iron composite drumsd. Aluminum and iron composite drumse. Solid and vented rotorsf. Uni-directional vented rotorsg. Drilled and slotted rotors

• Drum and rotor mounting methodsa. Fixed drums and rotorsb. Floating drums and rotors

• Brake drum and rotor wear and damagea. Drum taper wearb. Drum barrel wearc. Rotor taper variationd. Scoringe. Crackingf. Heat checkingg. Hard or chill spots

• Brake drum and rotor distortiona. Drum distortion

i. bellmouth drumsii. out-of-round drums

iii. eccentric drumsb. Rotor distortion

i. rotor lateral runoutii. rotor lack of parallelism

• Drum and rotor refinishinga. Drum and rotor turningb. Drum grindingc. Rotor resurfacingd. Drum and rotor metal removal limits

i. drum discard diameterii. rotor discard dimension

e. Special drum refinishing considerationsf. Special rotor refinishing considerations

i. special rotor metal removal limits1. rotor inner surface stock removal limit

ii. rotor surface finish1. determining rotor surface finish

• Pedals, levers and handles

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a. Parking brake controlsi. automatic parking brake release

b. Parking brake leversc. Parking brake handlesd. Electric parking brake switches

• Parking brake types• Electric• Mechanical/cable

• Parking brake linkagesa. Linkage rodsb. Linkage cablesc. Linkage leversd. Linkage equalizerse. Electric actuatorsf. Linkage design

i. single-cable linkagesii. dual-cable linkages

iii. multiple-cable linkagesg. Parking brake linkage adjustment

• Drum parking brakesa. Integral drum parking brakesb. Rear disc auxiliary drum parking brakesc. Driveline auxiliary drum parking brakes

i. external contracting band driveline auxiliary drum parking brakesii. internal expanding shoe driveline auxiliary drum parking brakes

• Caliper-actuated disc parking brakesa. Ball and ramp actuationb. Screw, nut and cone actuationc. Eccentric shaft and rod actuationd. Auxiliary disc parking brakes

• Ways to increase braking powera. Pedal forceb. Mechanical advantagec. Hydraulic advantaged. Vacuum advantage

• Power boostersa. Vacuum booster theory

i. air pressure - high and low1. meaeasuring vacuum2. booster vacuum supply

ii. vacuum booster suspension1. atmospheric-suspended power chambers2. vacuum-suspended power chambers

iii. vacuum check valves1. vacuum supply line filters

b. Integral vacuum booster operationi. brakes not applied

ii. brake applicationiii. brakes holdingiv. brakes fully appliedv. brake release

vi. brake pedal feel1. pedal feel with reaction disc2. pedal feel with reaction plate and levers

c. Multiplier vacuum boostersd. Hydraulic boosterse. Mechanical-hydraulic boostersf. Electro-hydraulic boostersg. Dual-power brake systems

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• ABS characteristicsa. ABS and tire traction

i. tire slip and braking distanceii. tire slip and vehicle stability

b. ABS is only an add-onc. ABS limitations

i. antilock system limitationsii. antilock system physical limitations

• ABS operation• System configurations

a. Four-channel ABSb. Three-channel ABSc. Single-channel ABSd. Integral and non-integral

• ABS componentsa. Wheel speed sensorsb. ABS control modulec. ABS warning lampd. Hydraulic modulator assemblye. Pump motor and accumulator

• Traction controla. Traction control operation

i. traction active lampii. traction control strategies

iii. traction deactivation switch• Various ABS• Brake shrouding• Suspension and braking

a. Suspension wear and damageb. Wheel alignmentc. Wheel bearings and braking

• Shop safety and practicesa. Lifts and hoistsb. Jacks and safety stands

• Cleaning toolsa. Brake vacuumsb. Brake washersc. Brushes and scrapersd. Parts washerse. Air compressors

• Chemical cleanersa. Non-petroleum based solventsb. Alcoholc. Detergents

• Brake toolsa. Adjusting tools

i. special wrenches1. bleeder screw2. flare nut3. torque wrenches

b. Tubing toolsi. tubing cutters

ii. tubing bendersiii. flaring tools

c. Assembly/disassembly toolsi. holddown spring tools

ii. return spring toolsiii. wheel cylinder removal toolsiv. caliper piston removers

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v. disc brake pad spreadersvi. wheel cylinder clamps

vii. parking brake spring toolsviii. dust boot tools

1. drivers2. rings3. pliers

ix. c-clampsx. swaging removal tools

d. Measuring toolsi. feeler gauges

ii. micrometersiii. dial indicatorsiv. shoe setting calipersv. drum micrometers

vi. cylinder bore go/no go gaugesvii. pedal effort gauge

viii. Tapley brake testing metere. Cylinder and caliper refinishing tools

i. drill motorsii. hone

f. Friction component refinishing toolsi. brake lathes

ii. drum grindersiii. rotor resurfacer

g. Hydraulic service toolsi. brake fluid syringe

ii. pressure bleeder• Brake system diagnosis

a. Talking to the customerb. Brake system road testingc. Road test procedure

i. driveline vibration testii. brake vibration test

iii. braking poweriv. braking stabilityv. brake pedal travel and feel test

vi. brake noised. Brake inspectione. Brake system diagnostic charts

i. pedal symptomsii. wheel brake symptoms

iii. brake performanceiv. brake noise

• Fluid related brake servicea. Fluid level checking

i. brake fluid inspectionii. brake fluid selection

iii. specific brake fluid level checks1. conventional brake system2. ABS

b. Brake bleedingi. bleeding sequences

ii. master cylinder bench bleeding1. manual bench bleeding2. basic bench bleeding3. reverse bench bleeding

iii. master cylinder on-car bleeding

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1. with bleeder screws2. without bleeder screws

iv. bleeding the wheel brakes1. manual bleeding2. vacuum bleeding3. gravity bleeding4. pressure bleeding5. surge bleeding

v. bleeding ABSc. Fluid changingd. Recentering pressure differential switches

i. single piston switch without centering springsii. single piston switch with centering springs

iii. two-piston switch with centering springs• Brake line, hydraulic valve and electrical component service

a. Brake line inspectioni. hoses

ii. tubingb. Brake hose replacement

i. removalii. installation

c. Brake tubing replacementd. Brake tubing fabrication

i. cuttingii. bending

iii. flaring1. SAE2. ISO

e. Hydraulic control valve servicei. metering valve tests

1. pressure bleeder test2. pressure gauge test

ii. proportioning valve testsiii. metering and proportioning valve replacementiv. proportioning valve adjustment

f. Brake electrical component servicei. electrical troubleshooting tools

ii. stoplight circuit tests1. lights always on2. lights never on

iii. mechanical stoplight switch adjustmentiv. stoplight switch replacementv. warning light circuit tests

1. warning light bulb tests2. parking brake switch test

vi. failure warning system switch tests1. pressure differential switch test2. fluid level switch tests

• Pedal assembly, master cylinder, and wheel cylinder servicea. Brake pedal assembly service

i. pedal linkage inspectionii. pedal freeplay adjustment

b. Master cylinder inspection and testingi. inspection

ii. testing1. quick-take-up valve test2. compensating port test3. external leak test4. internal leak test

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c. Wheel cylinder inspectiond. Master cylinder replacemente. Wheel cylinder replacementf. Hydraulic cylinder

• Overhaula. i. overhaul kits

ii. cylinder internal inspectioniii. bleeder screw removaliv. cylinder honingv. cylinder bore measurement

b. Master and wheel cylinder overhaul proceduresi. Ford cast-iron dual master cylinder

ii. General Motors aluminum QTU master cylinderiii. Two-piston wheel cylinder

• Drum Brake servicea. Brake drum removal

i. fixed drumsii. floating drums

b. Drum brake inspectioni. linings

ii. wheel cylinder and axleiii. hardware

c. Brake adjustingi. pedal travel test

ii. parking brake cautioniii. adjusting procedureiv. problem adjustmentsv. specific brake adjusters

1. starwheel brake adjustment2. cam brake adjustment3. wedge brake adjustment4. eccentric anchor5. slotted anchor

d. Brake shoe replacementi. disassembly

ii. inspectioniii. assembly

e. Initial brake adjustmenti. starwheel adjusters

ii. drum installedf. Brake shoe burnish-ing. Shoe replacement procedures

i. leading-trailing brakeii. dual-servo with cable type starwheel adjuster

iii. dual-servo with lever-type starwheel adjusteriv. leading-trailing brake with strut-quadrant adjuster

• Disc brake servicea. Brake pad inspection

i. on-carii. off-car

b. Brake pad replacementi. pad removal

ii. pad installationc. Brake pad burnish-ind. Brake caliper external inspection

i. Brake caliper overhaul bleeder screw removalii. brake caliper piston removal

1. mechanical2. compressed air

16        AUTO-1450: Automotive Braking Systems

3. hydraulic4. hydraulic service bench

iii. dust boot and piston seal removaliv. caliper internal inspection

1. piston2. caliper honing3. bore measurement

v. sleeved brake calipersvi. caliper assembly

1. piston seal installation2. piston and dust boot installation3. press fit dust boot installation4. retaining ring dust boot installation5. lip/groove dust boot installation

e. Brake pad replacement and caliper overhaul proceduresi. single piston floating

ii. single piston slidingiii. four piston fixediv. single piston rearv. single piston rear

• Brake drum and rotor machininga. Drum and rotor serviceb. Visual drum and rotor inspectionc. Brake drum measurement

i. inside diameterii. taper wear, barrel wear, and bellmouth distortion

iii. out-of-roundiv. eccentric distortion

d. Brake rotor measurementi. thickness

ii. taper variationiii. lateral runoutiv. lack of parallelismv. inner friction surface

• measurementa. Drum replacementb. Drum and rotor refinishing

i. metal removal considerationsii. maching new drums and rotors

c. Brake lathe operationi. lathe care

ii. mounting drums and rotorsiii. centering drums and rotorsiv. lathe settings

d. Turning a brake drume. Drum grinding proceduref. Rotor turning procedure

i. turning a brake rotor off the carii. turning a rotor on the car

iii. Resurfacing a brake rotor• Parking brake service

a. Parking brake testingi. brake pedal travel test

1. drum brakes2. disc brakes

ii. parking brake control testiii. release testiv. performance test

b. Parking brake adjustment

AUTO-1450: Automotive Braking Systems           17

i. shoe adjustmentii. cable adjustment

1. cable adjusters2. drum brakes3. disc brakes

c. Parking brake cable replacementi. freeing sticking and seized cables

ii. cable replacement procedures1. control cable2. ransfer cable3. application cable

d. Parking brake shoe and pad servicee. Vacuum release parking brake

• Power brake servicea. Vacuum booster testing

i. function testii. supply test

iii. leak testb. Vacuum booster output pushrod adjustment

i. pushrod adjustment testii. adjusting methods

c. Vacuum booster replacementd. Hydro-boost testing

i. pre-test inspectionii. function test

iii. power steering pump testiv. accumulator test

e. Hydro-boost replacementf. Hydro-boost bleeding

• Antilock brake basicsa. Service basics

i. ABS problem or a conventional brake problemii. brake symptoms

iii. preliminary checksiv. verifying ABS operation

1. dedicated system testers2. scan tools3. ABS simulators

v. diagnosis with the ABS warning lampb. Onboard diagnostics

i. fault code diagnostics1. multiple diagnostic trouble codes2. false codes

c. ABS performance checks, precautions and proceduresi. pump and accumulator checks

ii. wheel speed sensor service1. oscilloscope testing2. wheel speed sensor adjustment

iii. wheel speed sensor replacementd. General bleeding procedures

• Wheel bearing servicea. Types of wheel bearings

i. adjustable dual wheel bearingsii. sealed wheel bearings

iii. solid axle wheel bearingsb. Wheel bearing diagnosis

i. bearing noise tests1. road test2. shop test

ii. bearing feel tests

18        AUTO-1450: Automotive Braking Systems

iii. bearing grease seal testsiv. bearing axial play tests

c. Basic wheel bearing servicei. general bearing replacement tips

ii. wheel bearing cleaningiii. wheel bearing inspectioniv. wheel bearing lubrication

d. Adjustable dual wheel bearing servicee. Tapered roller bearing adjustment

i. hand adjustmentii. torque wrench adjustment

iii. dial indicator adjustmentf. Sealed wheel bearing replacement

i. rear axleii. front axle

g. Solid axle wheel bearing and seal servicei. c-lock axles

ii. retainer plate axle• Regenerative braking

• Fundamentals• Vehicle applications

• gasoline/electric hybrids• electric vehicles

ResourcesDuffy, James E. Modern Automotive Technology. 9th ed. Tinley Park, IL: Goodheart-Willcox, 2017. 

Erjavec, Jack and Ken Pickerill. Today's Technician: Automatic Transmissions and Transaxles. 6th ed. Boston, MA: Cengage Learning,2016. 

Erjavec, Jack. Automotive Technology: A Systems Approach. 6th ed. Boston, MA: Cengage Learning, 2014. 

Halderman, James D. Automotive Technology: Principles, Diagnosis, and Service. 5th ed. New York, NY: Pearson, 2015. 

Halderman, James D. Automotive Brake Systems. 7th. New York, NY: Pearson, 2017. 

Pickerill, Ken. Today's Technician: Automotive Brake Systems. 6th ed. Boston, MA: Cengage Learning, 2014. 

Johanson, Chris and Martin T. Stockel. Auto Brakes, A5 (G-W Training Series for ASE Certification. 4th ed. Tinley Park, IL: Goodheart-Willcox, 2015. 

Resources Other1. http://autorepair.about.com/od/troubleshooting/ss/ts_brakes.htm#step1 - Troubleshooting Brake Problems2. http://stoptech.com/technical-support/technical-white-papers/proportioning-valves (http://stoptech.com/technical-support/

technical-white-papers/proportioning-valves/) - Brake Proportioning Valves3. http://www.youfixcars.com/disc-brake-caliper.html - Disc Brake Caliper Problems4. http://what-when-how.com/automobile/hydraulic-braking-system-automobile/ - Automobile Hydraulic Braking System5. http://www.knowyourparts.com/technical-articles/brake-hydraulic-system/ - Brake Hydraulic System Inspection6. http://www.explainthatstuff.com/brakes.html. - Explain That Stuff - Brakes7. http://auto.howstuffworks.com/auto-parts/brakes/brake-types/emergency-brakes.htm - How Emergency Brakes Work8. http://www.carbibles.com/brake_bible.html - The Brake Bible9. http://www.carparts.com/brakes.htm - A Short Course on Brakes

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