Aurltb103 1

AURLTB103 Diagnose and repair light vehicle hydraulic
braking systems
Student Book
Written Assessment
AURLTB103 Diagnose and repair light vehicle hydraulic braking systems

braking systems
Assessment 1 – Questioning – Written Assessment
Student Name Prabin Thapa Student ID Number 12989
Unit Start Date 27/09/2021 Unit End Date 14/10/2021
Assessment Due Date 14/10/2021 Date Submitted 14/10/2021
This cover sheet is to be completed by the student and assessor and used as a record to
determine student competency in this assessment task
The assessment process and tasks were fully explained. Yes / No
I am aware of which evidence will be collected and how. Yes / No
I am aware of my right to appeal an assessment decision. Yes / No
Assessment 1 – Questioning – Version: Created: April 2017

Written Assessment – 2.0
AURLTB103 Page 2 of 41
I am aware that I can locate the AIBT’s Complaints and Appeals Policy and Procedure on Yes / No
their website at https://aibtglobal.edu.au/
I have discussed any additional educational support or reasonable adjustments I

require in order to undertake this assessment with the Student Support Services Yes / No
Officer and Trainer / Assessor, (if applicable). e.g. Student Handbook and Access and
Equity Policy https://aibtglobal.edu.au/
I have access to all required resources? Yes / No
Cheating & Plagiarism Declaration
Student Declaration: In accordance with the AIBT’s Academic Misconduct Policy, I hereby
acknowledge by signing this declaration that I have not cheated or plagiarised any work regarding
the assessment tasks undertaken in this unit of competency except where the work has been
correctly acknowledged.
NOTE: Student must sign this prior to submitting their assessments to the assessor
14 10 / _2021
Signature Prabin Thapa Date:
Satisfactory or Not Yet Satisfactory

Assessment Results
(Please circle or highlight the assessment result for
this task)
Feedback to Student - Please provide general feedback on the Student’s performance
Student Declaration: - I verify that the work Assessor Declaration: - I verify that I have
completed is my own and that I was adequately adequately explained and negotiated the
informed of the assessment process prior to assessment tasks with the student prior to
commencing this assessment task. commencing assessment.
Student Signature Prabin Thapa Assessor Signature

braking systems
Date Date
Context and Conditions of Assessment
This assessment will ensure that the elements, performance criteria, performance evidence
and knowledge evidence required and conditions are adhered to demonstrate competency in
this unit assessment task.
● Read the assessment carefully before commencing.
● This is an open book assessment and will be conducted at your designated campus /
workshop / specialised lab.
● Your Assessor will use the assessment criteria in this document and will provide feedback /
comment.
● You must answer all the questions in the assessment tasks in your own words and own
handwriting.

● Your Trainer / Assessor will inform you of the due date for this assessment task.
● Your Assessor will grade as either S – Satisfactory or NS – Not Satisfactory for the
assessment. In all cases your Assessor will provide you with feedback.
● Only when all assessment tasks have been graded as S – Satisfactory you will be deemed C
– Competent in the final result of the unit of competency; if you do not satisfactorily
complete all the assessment tasks you will be deemed NYC – Not Yet Competent.
Re-Assessment Conditions
● If the evidence is graded as NS – Not Satisfactory you will be required to re-submit the
evidence. In this case, you will be provided with clear and constructive feedback based on
the assessment decision so that they can improve your skills / knowledge prior to
reassessment.
● Where a ‘NS – Not Satisfactory’ judgement is made, you will be given guidance on steps to
take to improve your performance and provided the opportunity to resubmit evidence to
demonstrate competence. The assessor will determine and discuss the reasons for NS – Not
satisfactory on any of the criteria and will assess you through a different method of
assessment e.g. verbal/oral questioning, problem solving exercises.
● You will be notified between 10-30 working days of undertaking an assessment of their
result in achieving competency
o If a student does not complete the assessment, they should notify their trainer as to
why they did not complete the assessment and if due to illness, a medical
certificate must be produced.
o In the above scenario, student will be given an opportunity for reassessment within 5
working days with no reassessment fee charged.
o Students who are deemed to be Not Yet Competent (NYC) will be provided with
information identifying the areas in which they failed to achieve competency.
Students will then have the opportunity to repeat the assessment task within 5
working days of notification with no reassessment fee charged.
o If a student is deemed NYC in the reassessment or if the student did not approach
the AIBT’s within five working days with a valid reason for not availing themselves
of the reassessment opportunity, then those students will be given a final chance to
re-sit the assessment and will be charged a reassessment fee as per AIBT rule.
o After this no further reassessment attempt will be provided to the student and the
student will be required to repeat the whole unit with full fee for the unit. The
student will be made aware of the impact of repeating the unit may have on their
student visa.
o If a student is found to be cheating or plagiarising their assessment, a
reassessment fee will be charged for reassessing the assessment within 5 working
days.
o If the student is found to be plagiarising or cheating again after conclusion of the
Intervention meeting with the Course Co-ordinator, the matter will be referred to
the Academic Management Committee which may result in the suspension or
cancellation of their enrolment
o AIBT’s has intervention strategies, including student support services available to
enable students to complete qualification in the expected time frame. Students at
risk of not completing within this time frame are identified as early as possible and
an intervention strategy is put in place.

braking systems
AIBT will ensure access to:
● automotive repair workplace or simulated workplace

● workplace instructions
● manufacturer braking system specifications
● two different light vehicles with four-wheel hydraulic disc brake systems with faults
● one light vehicle with a rear drum brake system
● diagnostic equipment for light vehicle hydraulic braking systems
● tools, equipment and materials appropriate for repairing light vehicle braking systems

Evidence to be submitted by the student: -
Completed written responses to the questions in the assessment task
Assessment Decision Making Rules
Your assessor will assess the evidence submitted for the following elements, performance criteria,
performance evidence and knowledge evidence to confirm that the student evidence submitted
demonstrates validity, sufficiency, authenticity and confirms current skills and knowledge
relevant to the unit of competency.
Your assessor will be looking for the following in this assessment task: -
● work health and safety (WHS) and occupational health and safety (OHS)
requirements relating to diagnosing and repairing light vehicle hydraulic braking
systems, including procedures for:
o lifting and supporting light vehicles
o handling and controlling brake dust and brake fluids
● environmental requirements, including procedures for trapping, storing and disposing of
brake dust and brake fluid released from hydraulic braking systems
● operating principles of light vehicle hydraulic braking systems and associated components,
including:
o levers
o friction
o hydraulics, including the relationship between force, pressure and area
● properties of brake fluids, including:
o Department of Transportation (DOT) classification
o synthetic and non-synthetic
o compatibility of fluid types
● application, purpose and operation of light vehicle hydraulic braking systems and components,
including:
o front and rear split systems
o diagonal split systems
o master cylinders, including:
– tandem master cylinders
– compensating-type master cylinders
– centre-valve master cylinders
o drum braking system and components, including:
– self-energising or servo effect
– leading and trailing shoe braking systems
– duo-servo braking systems
– two-leading shoe braking systems
– wheel cylinders
– manual and self-adjustment systems of drum braking systems
o disc braking systems and components, including:
– types of brake discs
– disc pads
– self-adjustment of disc pads
– fixed, floating and dual-piston brake calipers
o parking brake systems and components, including:
– parking brake levers
– drum parking brakes

braking systems

– disc parking brakes
– electronic parking brake systems
o braking system valves and switches, including:
– pressure differential valves and switches
– proportioning valves
– load-sensing proportioning valves
– drum brake check valves
o fluid-level warning devices
o vacuum operated brake boosting systems
● diagnostic testing procedures for light vehicle hydraulic braking systems, including procedures
for:
o checking brake pedal
o operational tests of brake booster
o operational tests of master cylinder
o testing brake fluid
o operational tests of hand brake
o operational tests of drum and disc brakes
o measuring and evaluating brake drums, shoes, discs and pads
● repair procedures for light vehicle hydraulic braking systems, including procedures for:
o removing, replacing and adjusting hydraulic system components, including
master cylinder, proportioning valves, switches, brake hoses and lines, disc
calipers and wheel cylinders
o removing, replacing and adjusting braking system components, including brake
booster, master cylinder, hand brake lever and cables, brake shoes and drums,
brake pads and brake discs
o bleeding brakes, including anti-lock braking systems (ABS)
● post-repair testing procedures for light vehicle hydraulic braking systems, including
procedures for road testing and bedding in brakes.

braking systems
Assessment 1 – Questioning
Written Assessment
1. Identify five (5) important items of personal safety when diagnosing and repairing braking
systems?
1 Safety clothing
2 Ear plugs
3 Face protection
4 Safety Boots
5 Safety Gloves
2. List three (3) precautions when jacking a vehicle on the floor.
1 Ensure the axle stands after lift.
2 Check the level of the surface
3 Make sure to use the right lift points.

3. Why should safety stands be placed under a raised vehicle?
Safety stands must be always placed under a raised vehicle to prevent a major injury because
the jack can slip, and the vehicle can fall which can lead to a big physical damage.
4. What six (6) precautions should be observed if a vehicle is to be raised on a hoist?
1 Check the height limit.
2 Ensure all the doors are properly closed.
3 Make sure to use the correct lift points.
4 Centre of gravity.
5 Be careful with safe working

limit. 6 Lower to engage the
safety latch.

braking systems
5. What three (3) practical methods of reducing the spread of asbestos should be followed in the
workplace?
1 Keep the workplace clean and tidy and vacuum dust away.
2 Isolate and wash into a covered drain tub.
3 Dispose the PPE after using and only use it once.
6. When handling, trapping, storing and disposing of new or waste hydraulic fluid, which
document should you use to find this information?
MDS
7. The main function of brake fluid is
A. Lubrication
B. Power transmission
C. Cooling
D. None of these
8. How should waste hydraulic fluid be stored and disposed?
Waste hydraulic fluid should always be stored in a covered and bounded container and they
should be disposed through a licence holder contractor.
9. When changing the hydraulic brake fluid, what should you use to catch the waste fluid?
A. Brake bleeder
B. Mop bucket
C. Storm water drain
D. Funnel
10. Hydraulic brakes function on the principle of
A. Law of conservation of momentum

B. Law of conservation of energy
C. Pascal’s law
braking systems
D. None of the above

11. What are two (2) main aspects to dealing with asbestos in motor vehicle repairs?
1 Some parts used in gasket uses asbestos.
2 Some parts of clutch and brake may contain asbesetos.
12. The friction that is generated between the brake pads and rotors when the vehicle is
descending a steep hill is called .
A. Static
B.
Kinetic
C. Heat
D. Resistive
13. A vehicle waiting at a stop light with the brakes applied is held in place by friction.
A. Static
B. Kinetic
C. Both “static” and “kinetic”
D. Neither “static” nor “kinetic”
14. What is the coefficient of friction [COF]?
The coefficient of friction is the ratio of the frictional force resisting the motion of two surfaces
in contact to the normal force pressing the two surfaces together.
15. Friction is the use of a lever and fulcrum to create mechanical advantage.
True or False: True
16. The use of leverage increases force and increases distance by the same factor.
True or False: True
17. A fulcrum is the point at which one lever pivots or sits to apply force to another lever of
device. A seesaw would be an example.
True or False: True
18. Friction is the force that resists motion between the surfaces of two objects.
True or False: True
19. The minimum parking brake force is generally of gross vehicle mass(GVM)
A. 5%
B. 0%
C 15%
D
20%
20. A force of 150 pounds is applied to a master cylinder with a piston area of 1 square inch, how
much force is developed on a wheel cylinder that has a piston area of 2 square inches?
A. 75 pounds
B. 150
pounds C.
300 pounds
D. 450 pounds
21. Complete the following statement about hydraulic principles using the
following words. Words: Consistent, Decreased, Force, Hydraulic, Master,
Size, System, Wheel
A hydraulic system uses a brake fluid to transfer pressure from the brake pedal to the
pads or shoes. This transfer of pressure is reliable and consistent because liquids
are not compressible. That is, pressure applied to a liquid in a closed system is transmitted by
that liquid equally to every other part of that system . Apply a
force of 5 pounds (35 kPa) per square inch (psi) through the
master cylinder and you can measure 5 psi (35 kPa) anywhere in the lines and at each
wheel where the brakes operate.
The force can be increased at output (that is, at the wheel) by increasing the size
of the wheel’s piston, though piston travel decreases. The force at output can be
___decreased by
decreasing the size of the wheel piston, but the piston travel increases.
22. Name the four (4) Department of Transport (DOT) brake fluid classification.
1 DOT 5.1
2 DOT 5
3 DOT 4
4 DOT 3
23. Hygroscopic brake fluid absorbs moisture from the air.
True or False: TRUE
24. What colour is brake fluid?
A. Clear or amber
B. Red
C. Dark blue
D. Brown
25. As brake fluid absorbs moisture.
A. It becomes acidic
B. It becomes alkaline
C. It oxidises
D. Its boiling point drops
26. What is the “Dry” and “Wet” boiling point of the following brake fluids?
Dry Wet
DOT 3: 205 DEGREE C 140 DEGREE
C
DOT 4: 230 DEGREE C 155 DEGREE
C
DOT 5.1: 260 DEGREE C 180 DEGREE
C
27. All DOT 3 and DOT 4 brake fluid are fully synthetic brake fluid?
True or False: False
28. DOT 5 is a fully synthetic brake fluid?
True or False: True
29. Identify the two (2) dual brake system layouts.
Split diagonal front to rear and split front to rear are two dual brake system layouts.
30. Explain the operation of the “Front and Rear” brake split system.
Brake split system mostly uses front engine rear drive where the centre of gravity is 60/40 or
60% front mass, the brakes are split into two separate systems in case there is a failure in any
wheel in that case a backup system will retard the vehicle to stop.
31. What was the problem if the front brakes failed on the “Front and Rear” brake split system?
The weight transfer would reduce the load on the rear tyres, leading to poor traction and
therefore poor braking.
32. What happens in the event of a system failure on the “Diagonal” brake split system?
In the event of a system failure on the “ Diagonal “ brake split system 1 front and 1 rear brake
operation is an effort to pull the vehicle up in a straight line.
33. Explain the operation of the “Diagonal” brake split system.
Right front to left rear, left front to right rear are two of the separate circuits operating from a
tandem master cylinder.
34. Name the components of a dual master cylinder below.
1 Cap 7 Spring Seat
2 Dust Seal 8 Piston Spacer
3 Reservoir 9 Second Piston
4 Reservoir Seals 10 Spacer
5 Master Cylinder 11 First Piston

6 Return Spring 12 Circlip
35. The Functions of the master cylinder in the hydraulic brakes are.
The function of the master cylinder is to convert force into hydraulic pressure. It controls
slave cylinders located at the other end of the hydraulic brake system.
36. What is a tandem master cylinder?
Tandem master cylinder is a setup of two pistons, one behind the other with a common
piston axis, and operated by a single pushrod. They are space efficient and mechanically
safe way to set up braking for multiple wheels.
37. The two inlet ports in a master cylinder are the vent port and the replenishing port.
True or False: True
38. In a master cylinder, the vent port (forward port) has been called a compensating port.
True or False: True
39. A dual brake system uses a tandem master cylinder.
True or False: True
40. Tandem master cylinder consists of
A. one cylinder and one reservoir

B. two cylinders and one reservoir
C. one cylinder and two
reservoirs D. two cylinders and
two reservoirs
41. Brake fluid is stored above the master cylinder.
True or False: True
42. If the master cylinder has a large rear chamber and a smaller front chamber.
A. The large chamber supplies fluid for the rear drum

brake B. The large chamber supplies fluid for the
front disc brake
C. The vehicle has a dual diagonal split brake system
D. The vehicle has four (4) wheel disc brakes
43. The purpose of the master cylinder is to?
A. Generate the hydraulic pressure needed to apply the brake mechanisms
B. Automatically pump the brakes during panic stops
C. Supply mechanical force to the brake mechanisms
D. All answers are correct
44. The advantage of having a tandem master cylinder arrangement in automobiles is that it?
A. Enhances safety by serving two independent lines in a divided line brake circuit
B. Enhances safety by activating the brakes using vacuum pressure in the event of brake fluid
loss
C. Supplies equal fluid pressure to each line of a divided line brake circuit, thereby
preventing the brakes from dragging on one side
D. Boosts the brake fluid pressure to reduce the force required to depress the brake pedal
45. A master cylinder that has a bulge at the rear, near the mounting flange, is a type
master cylinder.
A. Self-compensating
B. Auto compensating
C. Dual stage
D. Quick take-up
46. The purpose of the master cylinder is to?
A. Generate the hydraulic pressure needed to apply the brake mechanisms

B. Automatically pump the brakes during panic stops
C. Supply mechanical force to the brake mechanisms
47. What is the function of the compensating port in the master cylinder?
The function of the compensating port in the master cylinder is to allow for the variations in
volume of the brake fluid due to changes in temperature. When the brakes are of the fluid can
then return to master reservoir of flow to the brake components.
48. What is a centre-valve master cylinder?
A centre-valve master cylinder helps to improve cylinder performance and seal durability with
ABS. They have a centre valve in the piston which performs instead of a compensating port.
49. Both non-servo drum brake leading and training shoes are self-energizing as the brakes are
applied and the vehicle is moving forward.
True or False: True
50. Duo-servo drum brakes are also known as what type of brake assembly?
A. Leading-trailing brakes
B. Self-energizing brakes
C. Non-servo brakes
D. None of these answers is correct
51. Both non-servo drum brake leading and training shoes are self-energizing as the brakes are
applied and the vehicle is moving forward.
True or False: True

52. Duo-servo drum brake systems use an adjusting screw assembly and spring to connect the
lower ends of the shoes.
True or False: True
53. On duo-servo drum systems, the forward brake shoe is often called the primary shoe.
True or False: True
54. On a duo-servo brake, the primary shoe is connected to the secondary shoe by the automatic
adjuster (star wheel) screw.
True or False: True
55. Name the components of the duo-servo and non-servo brake systems below.
1 Lower return spring 1 Wheel cylinder
2 Leading shoe spring 2 Leading shoe
3 Shoe pivot pin 3 Park brake lever
4 Training shoe return spring 4 Lower pivot block
5 Trailing shoe
6 Top return spring

7 Park lever pivot
pin
56. What is the difference between return springs and hold-down springs?
Return springs brings the shoe back away from the drum once brakes are released whereas the
hold-down springs are used to mount a shoe to a backing plate, providing a firm and slightly
flexible mounting.
57. What does the term duo-servo mean?
Duo-serving means the force increasing servo action of the brakes happens when the car is
moving in any direction either in forward or in reverse.
58. Complete the following statement about two-leading shoe braking system using the following
words.
Words: Action, Braking, Cylinder, Drum, Forces, Higher, Self-energising, Trailing,
Wheel This design has two single-acting wheel cylinders and these
produce a wedging
action on both the front and the rear shoes.
Each cylinder forces one end of its shoe outwards, and a self-
energising effect is imparted to each shoe due to drum rotation. The other end of
the shoe is located against the back of the wheel cylinder which acts as
an anchor. Therefore, both shoes provide equal forces , with a force
greater than that which could be applied by normal means.
Some vehicles, with drum brakes at both the front and rear, have two-leading-shoe
brakes at the front wheels and leading and trailing type brakes at the rear wheels. This
provides the
higher percentage of braking required for the front wheels of the vehicle.
59. Name the components of the Two-leading shoe braking
system below.
1 Top shoe
2 Adjuster wheel
3 Front cylinder
4 Front return spring
5 Shoe retainer
6 Backing plate
60. Name the parts of a wheel cylinder below.
1 Dust seal
2 Wheel cylinder cup
3 Expander spring
4 Cylinder piston
5 Hydraulic line in
6 Bleeder screw
7 Dust boot
8 Piston
9 Cup
10 Expander spring
11 Cup
12 Piston
13 Dust cap
61. The function of the wheel cylinder is to .
A. Convert hydraulic pressure to a mechanical force at the drum brakes

B. Maintain correct shoe position and clearance
C. Prohibit the shoe from following the movement of the rotating drum
D. Provide the rubbing surface area for the linings
62. The wheel cylinder bore is filled with brake fluid. When the pedal is depressed, additional brake
fluid is forced into the cylinder.
63. A self-adjuster screw mechanism (star wheel) are non-directional and can be positioned on
either the left or the right side of the vehicle.
True or False: True
64. The self-adjusters (star wheels) for the left side and the right side are interchangeable.
True or False: True
65. On most vehicles, the automatic adjuster system .
A. Is installed on the primary shoe

B. Is installed on the secondary shoe
C. Operates when the brakes are applied as the vehicle moves forward
D. Operates when the brakes are not applied
66. Self-adjustment occurs on most duo-servo brakes whenever the foot brake is applied while
backing up.
True or False : True
67. What tool is used to adjust the brake shoes before the drum is installed?
A. Drum micrometer
B. Dial indicator
C. Dial caliper
D. Shoe set gauge
68. Brake drum is made from........materials.
A. steel
B. Aluminium
C. Cast iron
D. All of above these
69. The lever that moves the star wheel on the self-adjuster is often called a(n) pawl.
True or False: True

70. What are the two basic types of brake rotors used on today’s vehicles?
Ventilated
disc Solid
disc
71. Solid rotors are usually found on .
A. The front brakes of small, compact vehicles

B. The rear brakes of vehicles with rear disc brakes
C. The front brakes of large pickup trucks and SUVs
D. Both “the front brakes of small, compact vehicles” and “the rear brakes of vehicles with rear
disc brakes”
72. A ventilated rotor helps cool the disc brake assembly.
True or False: True
73. Rotors are typically made from .
A.
Aluminium
B. Cast iron
C. Both “aluminium” and “cast iron”
D. Neither “aluminium” nor “cast iron”
74. Linings are to disc brake pads.
A. Riveted
B. Bonded
C. Both “riveted” and “bonded”
D. Neither “riveted” nor “bonded”
75. Which of the following is NOT used as a friction material in NAO brake pads?
A. Nut shells
B. Asbestos
C. Powdered metals
D. Graphite
76. Name three (3) types of brake lining friction materials.
1 Semi metallic
2 Aramid fibre
3 Glass fibre
77. Complete the following statement about self-adjusting calipers using the
following words. Words: Fluid, Hydraulic, Pads, Piston, Pressure, Retract, Ring,
Rotor, Slightly, Wear
A piston hydraulic (square-cut) seal prevents pressure leakage between the cylinder bore
wall and the piston. This rubber sealing _ring also acts as a retracting
mechanism for the piston when hydraulic pressure is released, causing the piston to
return in its bore. When
hydraulic pressure is diminished, the seal functions as a return spring to retract the
piston .
In addition, as the disc brake _pads wear, the seal allows the piston to move farther out
to adjust automatically for the wear without allowing fluid to leak. Since the brake pads
need to
retract only slightly after they have been applied, the piston moves back only
slightly into its bore. The additional brake fluid in the caliper bore keeps the piston out
and ready to clamp the surface of the rotor
.
78. Name the three (3) types of brake calipers used with disc brakes?
1 Dual piston solid
2 Dual piston floating
3 Single piston floating
79. A typical fixed caliper housing is designed with one caliper piston.
80. Sliding calipers move on bolts.
True or False: True
81. Name the parts of brake caliper below.

1 Pads
2 Calliper
3 Disc rotor
4 Calliper seal
5 Piston
6 Anti-vibration pad clip
7 Hydraulic entry
8 Bleeder
82. Explain the operation of an integral drum

parking brake.
The integral drum parking brake is on the inside of a disk brake system. This system uses
cables to engage the parking brake just as the same way a drum brake system.
83. Parking brake mechanisms provide a hydraulic force to apply the brake shoes and
keep the vehicle stationary.
84. Name the parts of the drum park brake assembly below.
1 Adjuster loop
2 Cable
3 Lever
4 Spreader
5 Brake shoe
6 Backing plate
85. A rear disc/drum parking brake uses the inside of each rear wheel hub and rotor assembly as a
parking brake drum.
braking systems
True or False: True
86. Rear disc parking brakes have a mechanism that forces the pads against the rotor hydraulically.
True or False: True

braking systems
87. Name the parts of the disc park brake assembly below.
1 Outer pad 1 Park lever
2 Rotor 2 Park ball bearing
3 Inner pad 3 Actuator
4 Self-adjuster thread 4 Calliper piston
5 Actuation lever 5 Pusher screw
6 Actuator shaft 6 Calliper housing
7 Calliper bore 10 Rotator shaft
8 Piston seal
9 Calliper piston
88. All of the following statements about some electric parking brakes are true EXCEPT:
A. They use a cable to apply the rear calipers.

B. They apply when the vehicle is placed in drive.
C. They are integrated with the theft deterrent system.
D. They use an auto-hold feature.
89. Electric parking brakes are controlled by the driver and the Powertrain Control Module (PCM).
True or False: True
90. Electronically operated parking brakes are released when the vehicle is taken out of park.
True or False: True

91. Complete the following statement about electric parking brake system using the following words.
Words: Brakes, Cables, Door, Electric, Emergency, Engage, Fails, Hydraulic, Lever, Linkage,
Mechanical, Network, Parking, Release, Rolling, System
Electrically operated parking brakes are becoming more common and are replacing
mechanical systems. These systems operate as a conventional
hydraulic brake for normal braking and as an electric brake for parking. With electric
parking brakes, there is no need for a parking brake lever or
pedal. This frees up space in the interior.
Electric parking brakes are seen as the first step toward brake-by-wire systems. Two
different techniques are currently being used by manufacturers. Some systems have an
electric motor mounted on
the rear brake calipers and others use an undercar motor to pull on the parking brake
cables .
When the caliper is fitted with a motor, there is no need for parking brake cables and lever .
The motor is controlled by the PCM. The system interfaces with the vehicle’s controller area
network (CAN) for continuous
monitoring and feedback. This allows the system to do many things
besides apply the parking brake, such as:
● Provide some control during emergency braking.

● Help stop the car if the hydraulic system fails .
● Automatically releases the parking brakes when the throttle is opened.
● Automatically engage when the ignition is turned off.
● Automatically engage when the driver’s door is opened.
● Keep the vehicle from rolling backward when stopped on a hill by applying the
rear brakes until the driver operates the clutch or throttle pedals.
92. The purpose of a pressure differential valve is to alert the driver if pressure is lost in either
portion of a dual braking system.
True or False: True
93. Complete the following statement about the pressure differential valve operation using the
following words. Words: Brake, Driver, Hydraulic, Pedal, Pressure, Switch, Warning
A pressure differential valve, in the event of a hydraulic leak, is used to
shut off one hydraulic circuit and operate a warning light switch. Its main purpose is to
tell the driver if pressure is lost in either of the two hydraulic systems. Since each
brake hydraulic system functions independently, it is
possible the driver might not notice immediately that pressure and braking are lost. When a
pressure loss occurs, brake pedal travel increases and pedal feel typically
becomes
soft, spongy, and much less firm. This results in a more-than-usual effort to slow and stop the
vehicle. Should the driver not notice the difference, the warning light is actuated by the
hydraulic system safety
switch .
94. A proportioning valve reduces fluid pressure to .
A. The front brakes during initial brake [low pedal force] application
B. The rear brakes during initial [low pedal force] brake application
C. The front brakes during hard
braking D. The rear brakes during
hard braking
95. Complete the following statement about the proportioning valve operation using the
following words. Words: Adjusts, Balance, Brakes, Fluid, Force, Rear, Valve
The proportioning valve (balance valve) is used to control rear brake pressures,
particularly during hard stops. When the pressure to the rear brakes reaches a
specified level, the proportioning valve overcomes the force of its spring-loaded
piston, stopping the flow of
fluid to the rear brakes. By doing so, it regulates rear brake system pressure and
force for the difference in pressure between front and rear brake systems. This
keeps front and rear braking forces in balance .
96. Describe the purpose of a height-sensing proportional valve.
The main purpose of height-sensing proportional valve is to detect if the vehicle is loaded as a
function of the position of the vehicle body comparative to the vehicle frame, and to control
fluid pressure linked to the rear brakes.
97. The actuator lever on the height-sensing proportioning valve is connected to the rear
suspension or lower shock absorber bracket.
True or False: True
98. A metering valve is found only on cars and trucks with.
A. Four-wheel disc brakes

B. Four-wheel drum brakes
C. Disc front and drum rear
brakes D. Dual diagonal brake
circuits
99. A metering valve delays front braking unit the rear brakes are applied.

100. A brake fluid lamp will illuminate on the instrument panel if the fluid is contaminated
and needs to be changed.
101. Low fluid level sensors are built into the brake fluid reservoir body or cap.
True or False: True
102. Brake fluid level is important to safe braking, many vehicles have a fluid level
switch that causes illumination of the instrument panel’s red brake warning lamp when the
fluid level is too low.
True or False: True
103. Name the parts of the vacuum brake booster below.
1 One way valve for vacuum
2 Vacuum chamber
3 Atmosphere chamber
4 Reaction disc
5 Control valve
6 Pedal pushrod
7 Diaphragm
8 Atmosphere void
9 Return spring
10 Master cylinder pushrod
11 Master cylinder
104. What checks and adjustments would you carry out on the brake pedal?
It is very crucial to check for the pedal pad condition, its free play and pivot free. When
checking brake pedal ensure to see if there are any wear and tear.
105. The owner of a vehicle complains the car is hard to stop. The technician doing the
diagnosis starts by pumping the brake pedal several times with the engine off, and then starts
the engine while holding firm pressure on the brake pedal. The pedal falls away slightly and
less pressure is needed to maintain the pedal in any position. This test proves that .
A. The master cylinder is working

B. The vacuum booster is working
C. The front brakes require adjustment
D. There is air in the hydraulic system
106. After replacing a vacuum booster, the brakes lock up on a road test.
A. There is air trapped inside the brake lines.

B. The power booster pushrod needs adjustment.
C. The master cylinder is leaking
D. None of these answers are correct
107. A technician is checking a car with an owner’s complaint of poor braking performance
and a low brake pedal. The master cylinder is full, and there are no signs of fluid leaks in the
brake system. When he holds firm pressure on the brake pedal, the pedal slowly drops. What
could be the problem?
A. Internally leaking master cylinder

B. Internally leaking caliper
C. Leaking wheel cylinder
D. Frozen pressure differential valve
108. A technician is diagnosing a vehicle with a braking system problem. When she removes
the filler cap to check the fluid level in the master cylinder, she notices that the rubber seal on
the cap is swollen and has begun to disintegrate. What could be the problem?
A. Water in the brake fluid

B. Petroleum-based lubricants in the fluid
C. Fluid overheating
D. Incorrect type of brake fluid
109. From the image below, explain what the technician is checking for?
The technician is checking for fluid water

retention in the given image.
braking systems
The technician is using a tester that are used to

determine water content that should heat the
brake fluid and not rely on conductivity. A tester
that heats the brake fluid to determine the
correct boiling point.
111. Describe how to test a parking brake.
A preparing brake is tested by checking if it can hold the vehicle when the engine at idle, and in
drive. By checking if it can hold the vehicle on slope without moving forward or backward.
Always, lever action at manufacturer’s specifications.
112. What three (3) checks should be made before conducting a road test for a brake problem?
1 Check the brake fluid level.
2 Ensure pedal is pumped to give a firm pedal.
3 Make sure the boosters are working.
113. A customer complains that the car pulls to the left during hard braking. An inspection
shows that the front pads and rear shoes are worn. After resurfacing the rotors and drums and
replacing the pads and shoes, a road-test reveals that the car still pulls to the left during hard
braking.
A. The wheel alignment should be checked

B. The tyres could be the problem and should be swapped left to right to check whether the
direction of the pull changes.
C. Both A and B are correct
D. None of the answers are correct
114. A grinding noise when the brakes are applied could be caused by .
A. Weak return springs

B. Weak hold-down springs
C. Worn shoes
braking systems

115. A clicking noise heard when the brakes are applied could be caused by .
A. Frozen star wheel

B. Play in the attachment of the pad or shoe
C. Brake fluid or grease on the linings
D. Scored drums
116. Brake rotors should be checked for?
A. Thickness
B. Parallelism
C. Runout
117. A dial indicator is used to measure runout on a disc rotor.
True or False: True
118. Complete the following statement about brake pad inspection using the
following words. Words: Calipers, Friction, Inspected, Manual, Minimum, Pads,
Plate, Replacement, Thinnest
Disc brake pads should be checked periodically. Some callipers have

inspection holes in the caliper body. If they do not, the pads can be inspected from the
outer ends of the caliper. If you are not sure the pads are worn enough to warrant
replacement , measure them at the thinnest part of the pad.
Compare this measurement to the minimum brake pad lining thickness listed in the
service manual , and replace the pads if needed. Typically, if the
friction material remaining on the backing plate is less than 1/8 inch (3.175
mm), the pads should be replaced.
The technician is measuring the disc thickness at 8

different points. He is checking for parallel,
thickness variation and minimum thickness with the
help of a micrometer.
braking systems
120. Drum brake linings should be replaced when linings are?
A. Worn to within 1/32 inch (.8mm) of the rivet head

B. Contaminated with oil or grease
C. Contaminated with brake
fluid D. All answers are
correct
121. List five (5) types of wear to look for when evaluating brake drums?
1 Scoring
2 Any heat damages
3 Look if it is out of shape
4 Check if it is over sized
5 Centre bore clearance
122. When must a wheel cylinder be replaced?
A wheel cylinder must be replaced when there is any leakage or is seized.
123. Explain the first step to remove the master cylinder.
Always start with removing the brake fluid.
124. Why should you plug the ends of the brake lines after disconnecting them from the master
cylinder?
To avoid hazard and to reduce spills and cap ends to stop dust or any air ingress.

125. After installing the master cylinder or any hydraulic component, why bleeding air out of
the hydraulic system is important?
Bleeding air out of the hydraulic system is important because air is compressible gas, and it will
not give a positive fluid displacement or pressure transfer in the fluid.
126. On some vehicles, the proportioning valves are built into the master cylinder body
and must be replaced as a complete assembly.
True or False: True
127. The brake fluid level switch is built in the master cylinder brake fluid reservoir,
and can only be replaced by replacing the brake fluid reservoir.
True or False: True
128. A technician is diagnosing a car that had both front brake hoses replaced 5,000
miles ago. An inspection reveals that the right front brake hose has ruptured. What was
the cause of the fault?
A. The specifications called for DOT 3 fluid; using DOT 4 fluid caused
the failure. B. The brake hose was twisted and stressed too much when
installed.
C. Both A and B answers are correct
D. None of these answers are correct
129. Floating calipers must be removed from the steering knuckle when replacing brake pads.
True or False: True
130. You need to support the brake caliper using safety wire while servicing the brakes.
True or False: True
131. What care must be taken when installing new or reconditioned wheel cylinders on cars
equipped with wheel cylinder piston stops.
The rubber dust boots, and the piston must be squeezed into the cylinder before it is
tightened into the backing plate. Otherwise, the pistons will jam against the piston stops
causing hydraulic fluid leakage and erratic brake performance.
132. C-clamp is used to push the piston back into its bore when replacing pads.
133. Adjust the vacuum booster pushrod screw to provide a slight pressure of
approximately 5 pounds against the gauge.
True or False: True
134. When removing the vacuum booster, the master cylinder must be removed.
True or False: True
135. When disassembling an unfamiliar brake assembly, work on one wheel at a time and
use the other wheel as a reference.
True or False: True
136. The primary or leading shoe is toward the front of the vehicle while the secondary or
trailing shoe is toward the rear of the vehicle.
True or False: True
137. After resurfacing a brake drum, using a lint-free cloth dipped in a special brake cleaning
solvent. She then allows the drum to dry before reinstallation
True or False: True
138. It is a good practice to replace disc brake hardware when replacing disc brake pads.
True or False: True

139. Complete the following statement about park brake cable replacement using the
following words. Words: Brake, Cable, Disconnect, Lever, Slide
Almost all vehicles have two rear parking brake cables that are
connected to the equalizer or adjuster. With the vehicle on a hoist, remove the cable
adjusting nuts. Then slide the front end of the rear cable from the
equalizer or from the front brake cable.
To remove the cable from a drum brake, first remove the wheel and brake drum.
Disconnect the end of the rear cable from the rear parking brake lever on
the rear shoe. Use the proper size offset box wrench or screwdriver to depress the conduit
retaining prongs and slide the pronged fitting out through the hole
in the backing plate.
140. When bleeding a dual diagonal split brake system, the bleeding sequence is usually .
A. LR-RR-RF-LF
B. RF-LF-LR-RR
C. RR-LF-LR-RF
D. LR-RF-RR-LF
141. While manually bleeding a brake system, loosens all the brake bleeder screws at the same
time.
142. Explain why bleeding air out of a hydraulic system is important.
Bleeding air out of the hydraulic system is important because air is compressible gas, and it will
not give a positive fluid displacement or pressure transfer in the fluid.
143. Complete the following statement about road testing and pad burnishing using the
following words.
Words: Brakes, Burnishing, Cool, Customer, Driving, Hard, Operate, Pads, Refinished, Road,
Rotor, Slow
New pads require burnishing to establish full contact with the rotor
and to heat and cure any resin left uncured in the friction material. Whether the rotors were
refinished or not, new pads do not initially make full
contact with the rotor surfaces but require a period of light wear to establish this
contact. Also, when brake linings are manufactured, some of the resin materials may remain
uncured until the brakes are put into service. If fresh pads are subjected to
hard braking, the resins can boil to the surface of the pads and
cause glazing when they cool. The pads then may never operate properly.
Burnish the brake pads during the initial road test by driving at 30 mph to 35 mph
(50 kph to 60 kph) and firmly but moderately applying the
brakes to fully stop the car. Do this five or six times with 20
seconds to 30 seconds of driving time between brake applications to let the pads cool .
Then drive at highway speeds of 55 mph to 60 mph (85 kph to 90 kph) and apply the brakes
another five or six times to slow the car to 20 mph (30 kph). Again, allow about 30
seconds of
driving time between brake applications to let the brake pads cool. Finally, advise the
customer to avoid hard braking for the first 100 miles of city driving or the first
300 miles of highway driving.
144. Consider the various checks that you would make after repairing brakes?
Some of the important things that need to be checked after repairing brakes are checking fluid
level and see for any leakages, feel the pedal, drive and see if the brake is working fine, ensure
there is no locking unusually. Check the pedal consistency, look for any smell, sticking and
pulsing.
145. Which source of information will give you the most detail about diagnosing and
repairing brakes on the vehicle you are working on?
A. Workshop manual
B. Owner’s manual
C. Google
D. Textbooks
146. Why is it very important that the Job Card is completed correctly?
A job card is a legal document that must be completed correctly for the record of the vehicle
history. It can be very helpful to work on the vehicle in the future if the job card id completed
correctly.

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AURLTB103 Diagnose and repair light vehicle hydraulic

AURLTB103 Diagnose and repair light vehicle hydraulic

Assessment 1 – Questioning – Written Assessment

Student Name Prabin Thapa Student ID Number 12989

Unit Start Date 27/09/2021 Unit End Date 14/10/2021

Assessment Due Date 14/10/2021 Date Submitted 14/10/2021

The assessment process and tasks were fully explained. Yes / No

I am aware of which evidence will be collected and how. Yes / No

I am aware of my right to appeal an assessment decision. Yes / No

Assessment 1 – Questioning – Version: Created: April 2017

I have discussed any additional educational support or reasonable adjustments I

Cheating & Plagiarism Declaration

Satisfactory or Not Yet Satisfactory

Student Signature Prabin Thapa Assessor Signature

AURLTB103 Diagnose and repair light vehicle hydraulic

Context and Conditions of Assessment

Assessment 1 – Questioning – Version: Created: April 2017

AURLTB103 Diagnose and repair light vehicle hydraulic

AIBT will ensure access to:

● automotive repair workplace or simulated workplace

Assessment 1 – Questioning – Version: Created: April 2017

Completed written responses to the questions in the assessment task

Assessment Decision Making Rules

AURLTB103 Diagnose and repair light vehicle hydraulic

Assessment 1 – Questioning – Version: Created: April 2017

AURLTB103 Diagnose and repair light vehicle hydraulic

2. List three (3) precautions when jacking a vehicle on the floor.

1 Ensure the axle stands after lift.

2 Check the level of the surface

3 Make sure to use the right lift points.

Assessment 1 – Questioning – Version: Created: April 2017

4. What six (6) precautions should be observed if a vehicle is to be raised on a hoist?

1 Check the height limit.

2 Ensure all the doors are properly closed.

3 Make sure to use the correct lift points.

5 Be careful with safe working

Assessment 1 – Questioning – Version: Created: April 2017

2 Isolate and wash into a covered drain tub.

3 Dispose the PPE after using and only use it once.

7. The main function of brake fluid is

8. How should waste hydraulic fluid be stored and disposed?

10. Hydraulic brakes function on the principle of

A. Law of conservation of momentum

D. None of the above

Assessment 1 – Questioning – Version: Created: April 2017

1 Some parts used in gasket uses asbestos.

2 Some parts of clutch and brake may contain asbesetos.

14. What is the coefficient of friction [COF]?

True or False: True

True or False: True

True or False: True

True or False: True

following words. Words: Consistent, Decreased, Force, Hydraulic, Master,

Size, System, Wheel

23. Hygroscopic brake fluid absorbs moisture from the air.

True or False: TRUE

24. What colour is brake fluid?

25. As brake fluid absorbs moisture.

True or False: False

28. DOT 5 is a fully synthetic brake fluid?

True or False: True

29. Identify the two (2) dual brake system layouts.

34. Name the components of a dual master cylinder below.