Chap 67

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Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition ©©2008

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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.

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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

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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!

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HOW BRAKES STOP VEHICLES
Brakes are an energy-absorbing mechanism that converts vehicle
movement into heat while stopping the rotation of the wheels.
All braking systems are designed to reduce the speed and stop a
moving vehicle and to keep it from moving if the vehicle is
stationary.
Service brakes are the main driver-operated brakes of the vehicle,

and are also called base brakes or foundation brakes.
See Figure 67–1.
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Figure 67–1 Typical vehicle brake system showing all typical components.
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Most vehicles built since the late 1920s use a brake on each wheel.
To stop a wheel, the driver exerts a force on a brake pedal. Force on
the brake pedal pressurizes brake fluid in a master cylinder.
This hydraulic force (liquid under pressure) is transferred through

steel lines and flexible brake lines to a wheel cylinder or caliper at
each wheel. Hydraulic pressure to each wheel cylinder or caliper is
used to force friction materials against the brake drum or rotor.
The heavier the vehicle and the higher the speed, the more heat the
brakes have to be able to absorb. Long, steep hills can cause the
brakes to overheat, reducing the friction necessary to slow and stop a
vehicle.
See Figures 67–2 and 67–3.
Continued
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Figure 67–3 When driving down long,steep
grades, select a lower transmission gear to
allow the engine compression to help
maintain vehicle speed.
Figure 67–2 Brakes change the energy of

the moving vehicle into heat. Too much
heat and brakes fail, as indicated on this
sign coming down from Pike’s Peak in
Colorado at 14,000 ft (4,300 m).
Continued
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DRUM BRAKES
Drum brakes are used on the rear of many rear-wheel-drive,
front-wheel-drive, and four-wheel-drive vehicles.
When drum brakes are applied, brake shoes are moved outward
against a rotating brake drum. The wheel studs for the wheels are
attached to the drum. When the drum slows and stops, the wheels
also slow and stop.
Drum brakes are economical to manufacture, service, and repair.

Parts are readily available and reasonably priced. On some
vehicles, an additional drum brake is used as a parking brake on
vehicles equipped with rear disc brakes.

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Figure 67–4 Typical drum brake assembly.
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Figure 67–5 Drum brake assembly as used on the right rear wheel.

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DISC BRAKES
Disc brakes are used on the front of most vehicles built since the
early 1970s and on the rear wheels of many vehicles.
A disc brake operates by

squeezing brake pads on
both sides of a rotor or
disc that is attached to
the wheel.
Figure 67–6
Typical disc brake assembly.
Due to the friction between

the road surface and the
tires, the vehicle stops.
Continued
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BRAKE DESIGN REQUIREMENTS
To summarize, events necessary to stop a vehicle include:
1. The driver presses on the brake pedal.
2. The brake pedal force is transferred hydraulically to a wheel
cylinder or caliper at each wheel.
3. Hydraulic pressure inside the wheel cylinder or caliper presses
friction materials (brake shoes or pads) against rotating brake
drums or rotors.
4. The friction slows and stops the drum or rotor. Since the drum
or rotor is bolted to the wheel of the vehicle, the wheel also
stops.
5. When the wheels of the vehicle slow and stop, the tires must
have friction (traction) with the road to stop the vehicle.
Continued
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All braking forces must provide for the following:
1. Equal forces must be applied to both the left and right sides of
the vehicle to assure straight stops.
2. Hydraulic systems must be properly engineered and serviced

to provide for changes as vehicle weight shifts forward during
braking.
Hydraulic valves must be incorporated into the hydraulic

system to permit the maximum possible braking forces but
still prevent undesirable wheel lockup.
Antilock braking systems (ABS) are specifically designed to

prevent wheel lockup under all driving conditions, including
wet or icy road conditions.
Continued
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3. The hydraulic system must use a fluid that will not evaporate
or freeze. The fluid has to withstand extreme temperatures
without boiling and must not damage rubber or metal parts of
the braking system.
4. The friction material (braking lining or brake pads) must be

designed to provide adequate friction between the stationary
axles and the rotating drum or rotor. The friction material
should be environmentally safe. Nonasbestos lining is
considered to be safe for the environment and the technician.
5. The design of the braking system should secure the brake

lining solidly to prevent the movement of the friction
material during braking.
Continued
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6. Most braking systems incorporate a power assist unit that
reduces driver effort but does not reduce stopping distance.
Vacuum from the intake manifold is the most commonly used

source of vacuum for power brake boosters. The engine itself
must be functioning correctly for proper operation of the
power vacuum booster.
NOTE: It is this movement of the friction material that causes brake

noise (squeal). Various movement dampers are used by the vehicle
manufacturers to help control any movement that does occur. It is
important that every technician restore the operation of all aspects of the
braking system whenever they are serviced, even the noise dampers.

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BRAKE SYSTEM CATEGORIES
Brake system components

can be classified into six
subsystem categories,
depending on function.
Figure 67–7
Typical brake system components.
Continued
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Apply System Driver starts operation of the system by pressing the
brake pedal or applying the parking brake. The apply system
includes all levers, pedals, or linkage needed.
Boost System Used on most vehicles to increase brake pedal force.
Hydraulic System Brake pedal force is transferred to the hydraulic

system, where force is directed to the wheel brakes.
Wheel Brakes Hydraulic pressure moves a piston, in a disc or

drum brake system, that uses friction to press material against a
rotating drum or rotor. Resulting friction slows wheel rotation.
Continued
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Brake Balance Control System Mechanical, electrical, and
hydraulic components ensure brakes are applied quickly,with
balanced pressure for safe operation. Components include
metering valves, proportioning valves, and antilock braking
system components.
Brake Warning Lights The red brake warning lamp lights

whenever a hydraulic system failure occurs. The amber ABS
warning lamp or dim red brake light indicates an ABS self-test
and/or a possible problem in the ABS system.
Continued
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Figure 67–9 The red brake warning lamp alerts the driver to a possible brake system fault.
Figure 67–10 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 assembly—motor,
threaded adjustment rods and a pedal
position sensor.
Figure 67–8 A typical adjustable pedal
Pedal and seat system position is usually assembly. Both the accelerator and the
included as part of memory seat function brake pedal can be moved forward and
rearward by using the adjustable pedal
and can be set for two or more drivers. position switch.

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ANTILOCK BRAKE SYSTEM OPERATION
The purpose of an antilock braking system (ABS) is to prevent
the wheels locking during braking, especially on low-friction
surfaces such as wet, icy, or snowy roads.
It is the friction between the tire tread and the road that does the
actual stopping of the vehicle. ABS does not mean a vehicle can
stop quickly on all road surfaces.
A locked wheel has less traction to the

road surface than a rotating wheel.
ABS uses sensors at the wheels to measure the wheel speed. If a

wheel is rotating slower than the others, indicating possible lockup
(for example, on an icy spot), the ABS computer will control the
brake fluid pressure to that wheel for a fraction of a second.
Continued
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If a wheel starts to lockup, the purpose of the ABS system is to
pulse the brakes on and off to maintain directional stability with
maximum braking force.
Many ABS units cause the brake pedal to pulse if the unit is
working in the ABS mode, a cause for concern for some drivers.
The pulsing brake pedal informs the driver that the ABS is being
activated.
Some ABS units use an isolator valve in the ABS unit to prevent
brake pedal pulsations during ABS operation. With these types of
systems, it is often difficult for the driver to know if and when the
ABS unit is working to control a locking wheel.
See Figure 67–11 for an overview of a typical ABS on a rear-

wheel-drive vehicle.
Continued
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Figure 67–11
Typical components of an antilock braking system (ABS) used on a rear-wheel drive vehicle.
Continued
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FEDERAL BRAKE STANDARDS
The statutes pertaining to automotive brake systems are part of the
Federal Motor Vehicle Safety Standards (FMVSS) established
by the United States Department of Transportation (DOT).
Several standards apply to specific components within the brake
system.
The overall service and parking brake systems are dealt with in
FMVSS 135, covering brake system safety by establishing
specific brake performance requirements.
It does not dictate the design of the system, although some

requirements may make older technologies impractical or
obsolete.
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Four parts of the brake system are specifically regulated:
Fluid reservoir and labeling
Dashboard warning lights
A method of automatic adjustment
A mechanically engaging, friction-type parking brake system
The majority of FMVSS 135 consists of a comprehensive test
procedure designed to reveal any weakness in a vehicle’s braking
system. The test is used by manufacturers to certify the braking
performance of all new vehicles available for public purchase.
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FMVSS 135 Brake Test The test procedure consists of up to 24
steps, depending on vehicle configuration and braking system.
The actual performance tests are made with the vehicle loaded to
both the manufacturer’s specified gross vehicle weight rating
(GVWR) and the lightly loaded vehicle weight (LLVW), with
certain applied brake forces.
There are precise instructions for every step of the test, including
the number of times the tests must be repeated, the sequence of
the testing, and the allowable stopping distance for the particular
type of vehicle.
Some highlights of the testing procedure follow.
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Adhesion Utilization (torque wheel method) For vehicles
not equipped with ABS, this test is performed at LLVW and
GVWR to determine if the brake system will make adequate
use of the road surface in stopping the vehicle.
Cold Effectiveness This test is performed at both GVWR and
LLVW, to determine if the vehicle will have sufficient stopping
power when the brake lining materials are not preheated by
previous stops.
High Speed Effectiveness This test is performed only on
vehicles capable of exceeding 78 mph (125 km/h) to determine
if the brake system will provide adequate stopping power for
all loading conditions. The allowable stopping distance is
calculated from the maximum speed the vehicle can attain.
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Stops with the Engine Off This test is for vehicles equipped
with brake power assist units. The vehicle, loaded to GVWR,
must stop within 230 ft (70 m), from a speed of 62 mph (100
km/h). This test must be repeated six times.
Antilock Functional Failure This test ensures that service
brakes will function correctly in the event of an antilock
functional failure, and the brake system warning indicator is
activated when an ABS electrical function failure occurs.
Variable Brake Proportioning System This test is performed
on vehicles equipped with either a mechanical or an electrical
variable proportioning system. It ensures that, in the event of a
failure, the vehicle can still come to a stop in an acceptable
distance. If the vehicle uses an electrically operated variable
brake proportioning system, the brake warning system must
immediately alert the driver of any electrical functional failure.
Continued
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Hydraulic Circuit Failure This test is performed to ensure
that the driver will be alerted via the brake warning system
indicator that a failure has occurred, and that the vehicle can
still be stopped in an acceptable distance.
Brake Power Assist Unit Inoperative This test makes sure
the service brake can stop the vehicle in an acceptable distance
with the brake power assist unit in an inoperative state. It is
performed on vehicles with brake power assist units turned off
or inoperative.
Parking Brake The parking brake alone will hold the vehicle
stationary in either the forward or reverse direction on a 20%
grade for a period of at least 5 minutes.
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Heating Snubs This procedure heats the brake system by
making a series of 15 stops from a high speed. A snub is a
controlled brake application. The vehicle is loaded to GVWR,
with rapid acceleration between each stop to minimize cooling
the brakes.
Hot Performance After the brake system has been heated by a
series of heating snubs, the hot performance test is
immediately performed. The vehicle is loaded to GVWR and
two stops are made. The stopping distance must be within
acceptable limits as specified in the test. This test ensures that
the brake system on the vehicle will not fade following a series
of high speed stops at GVWR.
Continued
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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.
Although these tests may seem extreme, remember that they are
only a minimum standard of performance.
Any brake repair work should also leave the brake system capable
of meeting FMVSS 135.

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BRAKE REPAIR AND THE LAW
Once an automobile leaves the factory, the responsibility for
maintaining the designed-in level of braking performance falls on
the owner of the vehicle. Owners look to trained automotive
technicians to service their brake systems.
Regardless of specific laws governing brake repair, a tech is
always liable for damage or injuries resulting from repairs
performed in an unprofessional or unworkmanlike manner.
There is only one acceptable goal when making brake system

repairs: to restore the system and its component parts so they
perform to original specifications.
The purpose of any repair is to

restore like-new performance.
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SUMMARY
1. Drum brakes are used on the rear of most vehicles.
2. Disc brakes are used on the front of most vehicles.
The six brake subsystems include: apply system, boost system,

hydraulic system, wheel brakes, brake balance control system
(which includes ABS), and brake warning lights.
3. An antilock braking system (ABS) pulses the hydraulic force to

the wheels to prevent the tires from locking up. A locked tire
has lower friction than a rolling tire.
Continued
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SUMMARY (cont.)
4. The federal brake standards covered in FMVSS 135 regulate
specific brake performance requirements, but not the actual
design of the braking system.

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end

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Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition ©©2008

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition ©©2008

base brakes • boost system • brake balance control

Department of Transportation (DOT) • disc brakes • drum

electric adjustable pedals (EAP)

Federal Motor Vehicle Safety Standards (FMVSS) •

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition ©©2008

lightly loaded vehicle weight (LLVW)

red brake warning lamp

service brakes • snub • wheel brakes

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition ©©2008

It has been estimated that the brakes on the average

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition ©©2008

Service brakes are the main driver-operated brakes of the vehicle,

See Figure 67–1.

This hydraulic force (liquid under pressure) is transferred through

See Figures 67–2 and 67–3.

Figure 67–2 Brakes change the energy of

Drum brakes are economical to manufacture, service, and repair.

See Figures 67–4 and 67–5.

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition ©©2008

A disc brake operates by

Due to the friction between

2. Hydraulic systems must be properly engineered and serviced

Hydraulic valves must be incorporated into the hydraulic

Antilock braking systems (ABS) are specifically designed to

4. The friction material (braking lining or brake pads) must be

5. The design of the braking system should secure the brake

Vacuum from the intake manifold is the most commonly used

NOTE: It is this movement of the friction material that causes brake

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition ©©2008

Brake system components

Boost System Used on most vehicles to increase brake pedal force.

Hydraulic System Brake pedal force is transferred to the hydraulic

Wheel Brakes Hydraulic pressure moves a piston, in a disc or

Brake Warning Lights The red brake warning lamp lights

See Figures 67–9 and 67–10.

Figure 67–10 The ABS dash warning lamp

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition ©©2008

A locked wheel has less traction to the

ABS uses sensors at the wheels to measure the wheel speed. If a

See Figure 67–11 for an overview of a typical ABS on a rear-

It does not dictate the design of the system, although some

Some highlights of the testing procedure follow.

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition ©©2008

There is only one acceptable goal when making brake system

The purpose of any repair is to

2. Disc brakes are used on the front of most vehicles.

The six brake subsystems include: apply system, boost system,

3. An antilock braking system (ABS) pulses the hydraulic force to

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition ©©2008

Automotive Technology: Principles, Diagnosis, and Service, 3rd Edition ©©2008

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