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© 2011 Pearson Education, Inc.All Rights Reserved
Automotive Technology, Fourth EditionJames Halderman
DISC BRAKES
101
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
ObjectivesObjectives
• The student should be able to:– Prepare for the Brakes (A5) ASE
certification test content area “C” (Disc Brake Diagnosis and Repair).
– Describe how disc brakes function. – Name the parts of a typical disc brake
system.– Describe the construction of disc brake
pads.
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
ObjectivesObjectives
• The student should be able to:– Describe the difference between fixed
caliper and floating or sliding caliper.– Explain the difference between a standard
caliper and a low-drag caliper.
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
DISC BRAKESDISC BRAKES
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc BrakesDisc Brakes
• Parts and Operation– Piston(s) squeeze friction material (pads)
on both sides of rotating disc (rotor)– Used on front wheels of late-model vehicles
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc BrakesDisc Brakes
• Parts and Operation– Used on rear wheels of increasing number
of automobiles– Adopted because supply greater stopping
power than drum brakes with less likelihood of fade
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc BrakesDisc Brakes
• Disc Brake Advantages– Friction assembly has several significant
strong points– Only a few relatively minor weak points
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Figure 101-1 An exploded view of a typical disc brake assembly.
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc BrakesDisc Brakes
• Disc Brake Advantages– Fade resistance
• Cooling ability helps avoid heat-induced fade– All major parts exposed to air– Have greater swept area
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc BrakesDisc Brakes
• Disc Brake Advantages– Fade resistance
• Resistant to all kinds of fade– Mechanical fade– Lining fade
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc BrakesDisc Brakes
• Disc Brake Advantages– Fade resistance
• Resistant to all kinds of fade– Gas fade– Water fade
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Figure 101-2 Braking force is applied equally to both sides of the brake rotor.
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Figure 101-3 Disc brakes can absorb and dissipate a great deal of heat. During this demonstration, the brakes were gently applied as the engine drove the front wheels until the rotor became cherry red. During normal braking, the rotor temperature can exceed 350°F (180°C), and about 1,500°F (800°C) on a race vehicle.
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Figure 101-4 Slots and holes in the brake linings help prevent gas and water fade.
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc BrakesDisc Brakes
• Disc Brake Advantages– Self-adjusting ability
• Any wear of linings automatically compensated for by action of brake caliper
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc BrakesDisc Brakes
• Disc Brake Advantages– Self-adjusting ability
• When brakes applied, caliper pistons move out as far as needed to force brake pads into contact with rotor
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc BrakesDisc Brakes
• Disc Brake Advantages– Self-adjusting ability
• When brakes released, piston retracts only small distance dictated by rotor runout and piston seal flex
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Figure 101-5 The square-cut O-ring not only seals hydraulic brake fluid, but also retracts the caliper piston when the brake pedal is released.
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc BrakesDisc Brakes
• Disc Brake Advantages– Freedom from pull
• Stops straighter under wider range of conditions than drum brake
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc BrakesDisc Brakes
• Disc Brake Advantages– Freedom from pull
• Are not self-energizing to increase braking power
– Effects of loss of friction on one side far less pronounced
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc BrakesDisc Brakes
• Disc Brake Disadvantages– No self-energizing or servo action
• Contributes to poor parking brake performance
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc BrakesDisc Brakes
• Disc Brake Disadvantages– No self-energizing or servo action
• Requires driver to push harder on brake pedal for given stop
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc BrakesDisc Brakes
• Disc Brake Disadvantages– No self-energizing or servo action
• High pedal pressure eliminated through use of brake power boosters
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc BrakesDisc Brakes
• Disc Brake Disadvantages– Brake noise
• Sometimes make various squeaks and squeals during application
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc BrakesDisc Brakes
• Disc Brake Disadvantages– Brake noise
• Usually caused by high-frequency rattling or vibration of brake pads
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc BrakesDisc Brakes
• Disc Brake Disadvantages– Brake noise
• Antirattle clips help prevent vibration
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc BrakesDisc Brakes
• Disc Brake Disadvantages– Brake noise
• Shims between brake pad and caliper piston damp vibrations
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc BrakesDisc Brakes
• Disc Brake Disadvantages– Brake dust– Poor parking brake performance
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Figure 101-6 Antirattle clips reduce brake pad movement and vibration.
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Figure 101-7 Antivibration shims are used behind the pads on many disc brake caliper designs.
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
DISC BRAKE DISC BRAKE CONSTRUCTIONCONSTRUCTION
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc Brake ConstructionDisc Brake Construction
• Caliper– Hydraulic pressure creates mechanical
force to move brake pads into contact with brake rotor
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc Brake ConstructionDisc Brake Construction
• Caliper– Front axle: caliper mounts to spindle,
caliper support bracket or steering knuckle– Rear axle: mount to support bracket on
axle flange or suspension
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Figure 101-8 This brake caliper attaches to the front spindle.
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Figure 101-9 A rear disc brake caliper often attaches to a mounting bracket on the rear axle housing on this rear-wheel-drive vehicle.
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc Brake ConstructionDisc Brake Construction
• Splash Shield– Front axle: bolts to front spindle or steering
knuckle– Rear axle: bolts to axle flange or
suspension adapter plate– Protect inner side of brake rotor from water
and other contaminants
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
DISC BRAKE PADSDISC BRAKE PADS
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc Brake PadsDisc Brake Pads
• Brake Pad Assembly– Block of friction material attached to
stamped steel backing plate– Some pad backing plates have tabs that
bend over caliper to hold pad in place
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc Brake PadsDisc Brake Pads
• Brake Pad Assembly– Others have tabs with holes in them
• Pin slips through holes and fastens to caliper body to hold pads
– Still others have retainer spring that locks pad to caliper piston
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Figure 101-10 A typical disc brake pad.
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Figure 101-11 To prevent noise, bent tabs on the backing plate hold some brake pads to the caliper housing.
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Figure 101-12 Holes in the backing plate are a common method of locating a pad in the caliper.
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc Brake PadsDisc Brake Pads
• Brake Pad Assembly– Lining material can be one of a number of
products– Can be fastened to backing plate in several
ways
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc Brake PadsDisc Brake Pads
• Brake Pad Assembly– Edges of lining material usually
perpendicular to rotor surface– A few larger pads have tapered edges to
help combat vibration and noise
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Figure 101-14 The lining edges of some brake pads are tapered to help prevent vibration.
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc Brake PadsDisc Brake Pads
• Pad Wear Indicators– Used for safety reasons– Signal driver when pad replacement
necessary
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc Brake PadsDisc Brake Pads
• Pad Wear Indicators– Mechanical: squealing or chirping noise
when brakes are not applied made by tab contacting rotor
– Electrical: coated electrode in lining generates signal to turn on warning light
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Figure 101-15 Typical pad wear sensor operation. It is very important that the disc brake pads are installed on the correct side of the vehicle to be assured that the wear sensor will make a noise when the pads are worn. If the pads with a sensor are installed on the opposite side of the vehicle, the sensor tab is turned so that the rotor touches it going the opposite direction. Usually the correct direction is where the rotor contacts the sensor before contacting the pads when the wheels are being rotated in the forward direction.
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Figure 101-16 Electrical wear indicators ground a warning light circuit when the pads need replacement.
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc Brake PadsDisc Brake Pads
• Pad Assembly Methods– Riveted linings
• Brake block attached to backing plate with metal rivets
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc Brake PadsDisc Brake Pads
• Pad Assembly Methods– Bonded linings
• Glue brake block directly to shoe pad backing plate
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc Brake PadsDisc Brake Pads
• Pad Assembly Methods– Mold-bonded linings
• Combines advantages of bonding with mechanical strength of riveting
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Figure 101-17 Mold-bonded linings are commonly used in many applications.
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc Brake PadsDisc Brake Pads
• Brake Lining Composition– Ingredients mixed and molded into shape
of finished product– Fibers in material only thing holding
mixture together
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc Brake PadsDisc Brake Pads
• Brake Lining Composition– Large press forces ingredients together to
form brake block, which becomes brake lining
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
CHART 101–1 Typical compositions for asbestos (organic) lining used on older vehicles.
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc Brake PadsDisc Brake Pads
• Brake Lining Composition– Semimetallic friction material
• Uses metal rather than asbestos in its formulation
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc Brake PadsDisc Brake Pads
• Brake Lining Composition– Semimetallic friction material
• Require very smooth finish on rotor
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
CHART 101–2 Typical compositions for semimetallic disc brake pads
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc Brake PadsDisc Brake Pads
• Brake Lining Composition– Nonasbestos friction material
• Use synthetic material such as aramid fibers instead of steel
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc Brake PadsDisc Brake Pads
• Brake Lining Composition– Carbon fiber friction material
• Newest and most expensive of the lining materials
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc Brake PadsDisc Brake Pads
• Brake Lining Composition– Ceramic friction material
• Most pads today are ceramic and use little, if any steel
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Disc Brake PadsDisc Brake Pads
• Edge Codes– Lining edge codes help identify coefficient
of friction– First letter indicates coefficient of friction
when brakes are cold– Second letter indicates coefficient of
friction when brakes are hot
?
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
CHART 101–3 The SAE brake pad edge codes are used to indicate the coefficient of friction of the pad material.
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
BRAKE ROTORSBRAKE ROTORS
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Brake RotorsBrake Rotors
• Provides friction surfaces for brake pads to rub against
• Largest and heaviest part of disc brake
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Brake RotorsBrake Rotors
• Usually Made of Cast Iron– Solid rotors most often used on rear-wheel
disc brakes– Vented rotors have radial cooling passages
cast between friction surfaces
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Figure 101-18 Disc brake rotors can be either solid or vented.
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
CALIPER DESIGNSCALIPER DESIGNS
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Caliper DesignsCaliper Designs
• Fixed Caliper Design– Body manufactured in two halves– Uses two, four, or six pistons to apply brake
pads
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Caliper DesignsCaliper Designs
• Fixed Caliper Design– Caliper rigidly mounted to suspension– When brakes applied, pistons extend from
caliper bores and apply brake pads with equal force from both sides of rotor
– No part of caliper body moves when brakes applied
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Figure 101-19 (a) Many fixed caliper disc brakes use a simple retaining pin to hold the disc brake pads. (b) Removing the retainer pin allows the brake pads to be removed. (c) Notice the cross-over hydraulic passage that connects both sides of the caliper.
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Caliper DesignsCaliper Designs
• Fixed Caliper Advantages– Large and heavy, and can absorb and
dissipate great amounts of heat– Allows brake rotor and pads to run cooler
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Caliper DesignsCaliper Designs
• Fixed Caliper Advantages– Able to withstand greater number of
repeated hard stops without heat-induced fade
– Does not flex as much as other designs
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Caliper DesignsCaliper Designs
• Fixed Caliper Disadvantages– Add significant weight to vehicle– Service more difficult and greater
opportunity for leaks– Greater possibility of cracking
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Caliper DesignsCaliper Designs
• Floating and Sliding Caliper Design– Used in front brakes of most vehicles– Caliper free to move within limited range
on anchor plate solidly mounted to vehicle suspension
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Caliper DesignsCaliper Designs
• Floating and Sliding Caliper Design– When brakes applied, caliper piston applies
inner brake pad– At same time, caliper body moves in
opposite direction on anchor plate and applies outer brake pad
– Caliper body moves every time brakes applied
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Figure 101-20 This floating caliper mounts on a separate anchor plate that bolts to the vehicle suspension.
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Figure 101-21 Hydraulic force on the piston (left) is applied to the inboard pad and the caliper housing itself. The reaction of the piston pushing against the rotor causes the entire caliper to move toward the inside of the vehicle (large arrow). Since the outboard pad is retained by the caliper, the reaction of the moving caliper applies the force of the outboard pad against the outboard surface of the rotor.
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Caliper DesignsCaliper Designs
• Normal Caliper Operation– Piston moves just enough to distort caliper
seal– Returns to original position when brake
pedal released
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Caliper DesignsCaliper Designs
• Normal Caliper Operation– As wear occurs, additional brake fluid
needed behind piston– Comes from master cylinder; brake fluid
level drops as brake pads wear
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Caliper DesignsCaliper Designs
• Floating and Sliding Caliper Advantages– Lower cost, simple construction, and
compact size– Smaller size allows better packaging of
caliper on vehicle
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Caliper DesignsCaliper Designs
• Floating and Sliding Caliper Disadvantages– Certain degree of flex, which can contribute
to spongy brake pedal– Flex also allows caliper body to twist
slightly when brakes applied, causing tapered wear of lining material
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Caliper DesignsCaliper Designs
• Floating and Sliding Caliper Disadvantages– Do not have mass of fixed calipers– Flexible mounting systems slow transfer of
heat from caliper body to anchor plate that aids cooling
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Figure 101-22 Caliper flex can cause tapered wear of the brake lining.
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Caliper DesignsCaliper Designs
• Floating Caliper Operation– Body of floating caliper does not make
direct contact with anchor plate– Body supported by bushings and/or O-rings
• Allow it to “float” or slide on metal guide pins attached to anchor plate
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Caliper DesignsCaliper Designs
• Floating Caliper Operation– Depend on proper lubrication of pins,
sleeves, bushings, and O-rings for smooth operation
– Special high-temperature brake grease must be used
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Figure 101-23 A typical single-piston floating caliper. In this type of design, the entire caliper moves when the single piston is pushed out of the caliper during a brake application. When the caliper moves, the outboard pad is applied against the rotor.
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Figure 101-24 Floating calipers are supported by rubber O-rings or plastic bushings.
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Figure 101-25 Metal guide pins and sleeves are used to retain and locate floating calipers.
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Caliper DesignsCaliper Designs
• Sliding Calipers– Body of sliding caliper mounts in direct
metal-to-metal contact with anchor plate
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Caliper DesignsCaliper Designs
• Sliding Calipers– Calipers move on ways cast and machined
into caliper body and anchor plate
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Caliper DesignsCaliper Designs
• Sliding Calipers– Retaining clips and design of caliper
prevent body from coming out of ways– Depend on good lubrication of ways for
proper operation
?
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Figure 101-27 Exploded view of a typical sliding brake caliper.
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Figure 101-28 Sliding calipers move on machined ways.
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
REAR DISC BRAKESREAR DISC BRAKES
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Rear Disc BrakesRear Disc Brakes
• Four-wheel disc brake systems have become more common
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Rear Disc BrakesRear Disc Brakes
• Rear Disc Parking Brakes– Two methods of providing parking brakes
when rear discs are installed• Adapt disc brake to also function as parking
brake
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Rear Disc BrakesRear Disc Brakes
• Rear Disc Parking Brakes– Two methods of providing parking brakes
when rear discs are installed• Use mechanically actuated drum brakes
inside rear rotors
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Figure 101-29 Exploded view of a typical rear disc brake with an integral parking brake. The parking brake lever mechanically pushes the caliper piston against the rotor.
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Figure 101-30 This single-piston brake caliper is mechanically actuated to serve as a parking brake.
101 DISC BRAKES
Automotive Technology, Fourth EditionJames Halderman
© 2011 Pearson Education, Inc.All Rights Reserved
Figure 101-31 Drum parking brakes are fitted inside the rotors on this vehicle equipped with rear disc brakes.