Name _________________

Brake System Overhaul Lab

Possible
Prepare a complete work order for the vehicle(s) being serviced. (you may complete front
& rear brakes on separate vehicles)

Perform a complete brake system inspection and detail the components you have checked
on the work order (complete with NATEF #’s)

List the components that need replacing here and list the flat rate time and estimate of parts
according to the parts & time guide

Will you be re-packing the front wheel bearings? ____ yes ____ no
(B36 & B41 if replacing)
Will you be re-packing the rear wheel bearings? ____ yes ____ no

Note to student
If you are performing this exercise on a LBCC owned vehicle you will perform all
machining operations on separate (dummy) parts. All other adjustments and procedures
are to be made on actual vehicle.

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 Disc Brake Overhaul
Demonstrate and record measurements of front disc brake rotor.

_____ Rotor thickness _____ Minimum allowable thickness

_____Taper variation _____ Maximum allowable taper variation

_____ Measured lack of parallelism _____ Maximum allowable lack of parallelism

I will (select one) A) Machine this rotor B) Resurface (swirl finish) this rotor

Torque specifications used to install the rotor and/or caliper

Wheel bearing torque _________ Caliper torque _______ Caliper frame torque _______

What steps have you taken to insure the new disc brake pads will not squeal??

Before installing wheel demonstrate your inspection procedure, lubrication, and final
assembly of the disc brakes

Wheel Lug Nut Torque specification _______ Torque actually used ______

Discuss common causes of disc brake noise, poor stopping, pulling, dragging (not
releasing), or pedal pulsation (B-20)

If you are working on a disc brake parking brake system talk with instructor and get
signature

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 Drum Brake Overhaul
How will you protect yourself from brake dust when working on this drum brake system?

Measure the brake drum _____ actual diameter _____ maximum diameter
I will (select one) A) Machine this brake drum B) Replace this brake drum

After machining what did you do to prepare the drum surface for installation?

_____ measurement of brake drum diameter after machining

_____ discard diameter of this brake drum

(circle one) This drum is .030” or more smaller than the discard diameter A) yes B) no

After removing all drum brake components, and prior to any reassembly (except wheel
cylinder) demonstrate how you have serviced the backing plate and parking brake cables.

Assemble drum brake components and demonstrate how you are pre-adjusting the brake
shoes (prior to installing brake drum)

Instructor Check (verification of proper assembly) _____ Left side _____ Right side

Explain to the instructor what can cause poor stopping, pulling, noise, brake drag or pedal
pulsation on a drum brake system

Wheel Lug Nut Torque specification _______ Torque actually used ______

see page 4 (over)

I:\brakes_suspension powerpoint\Lab assignments\Brake System Overhaul Lab.doc

 Final Adjustment and Service

Flush and bleed all four brakes. List the procedure used.

Demonstrate your final drum brake adjustment technique

Demonstrate final parking brake adjustment technique

_____ Brake Pedal free play _____ Effective Travel (distance to floor after free play)

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