Brakes Printable

by
Russell Krick
Publisher
The Goodheart-Willcox Co., Inc.

Tinley Park, Illinois
Goodheart-Willcox Co., Inc.
Permission granted to reproduce for educational use only
Basic brake system

Braking ratio
Brake system hydraulics
Brake system components
Parking brakes
Automotive Brakes
Provide a means of using friction to
slow, stop, or hold the wheels of a
vehicle
When a car is moving, it has kinetic
energy (inertia)
To stop the vehicle, the brakes convert
mechanical (moving) energy into heat
Brake Operation
When the driver pushes on the brake
pedal, lever action pushes a rod into
the brake booster and master cylinder
The pressure developed in the master
cylinder forces fluid through the brake
lines to the wheel brake assemblies
The brake assemblies use this
pressure to cause friction for braking
Parking Brake
The parking brake system uses cables
or rods to mechanically apply the rear
brakes
Provides a system for holding the
wheels when the vehicle is parked on a
hill or stopping the vehicle during
complete hydraulic brake system failure
Drum and Disc Brakes

Two common types of brake
assemblies:
Disc brakes
often used on the front wheels
Drum brakes
often used on the rear wheels
Drum and Disc Brakes
Disc brakes
Drum brakes
Comparison of front wheel braking

effort to rear wheel braking effort
When a vehicle stops, its weight tends
to transfer onto the front wheels
The rear tires lose some of their grip
The front wheels must do more of the
braking
Typical Braking Ratios

Rear-wheel-drive vehicles:
front brakes may handle 60% to 70% of
the braking, rear brakes handle 30% to
40%
Front-wheel-drive vehicles:
more weight is concentrated on the front
wheels
braking ratio is even higher at the front
wheels
Automotive brakes use a hydraulic

system
Hydraulic brakes use confined brake
fluid to transfer brake pedal motion and
pressure to each of the wheel brake
assemblies
Hydraulic Principles
Liquids in a confined area will not
compress
When pressure is applied to a closed
system, pressure is exerted equally in
all directions
Hydraulics can be used to increase or
decrease force or motion
Hydraulic System
Action
Pressure and motion can be
transferred from one cylinder to another
Cylinders of the same size:
if one piston is moved, the other will move
the same amount with the same force
Cylinders of different sizes:

if the smaller piston is moved, the larger
piston will move with more force, but it will
move a shorter distance
Hydraulic System
Action
In a hydraulic jack, a
small piston acts on a
large piston, resulting in
great force, but a small
amount of movement
Hydraulic System
Action
Hydraulic jack operation

Hydraulic Brake Action

The master cylinder acts as the
pumping piston that supplies system
pressure
The wheel cylinder acts as the power
piston, moving the friction linings into
contact with the rotating drums or discs
Hydraulic Brake Action
Brake Pedal Assembly
A lever arm to increase the force applied

to the master cylinder piston
Master Cylinder
Foot-operated pump that forces fluid to
the brake lines and wheel cylinders
Develops pressure to apply the brakes
Equalizes pressure required for braking
Keeps the system full of fluid as the
linings wear
May maintain a slight pressure to keep
contaminants from entering the system
Master Cylinder
Brakes applied
Brakes released
Master Cylinder
Components
Master Cylinder
Components
Cup and piston
used to pressurize the system
when they are pushed forward, they trap
fluid, building pressure
Intake port
allows fluid to enter the rear of the
cylinder as the piston slides forward
fluid flows from the reservoir, into the area
behind the piston and cup
Master Cylinder
Components
Compensating port
releases pressure when the piston
returns to the released position
fluid can flow back into the reservoir
through the compensating port
Residual pressure valves

maintain residual fluid pressure of
approximately 10 psi (69 kPa) to help
keep contaminants out of the system
Master Cylinder
Components
Rubber boot
prevents dust, dirt, and moisture from
entering the back of the master cylinder
Reservoir
stores an extra supply of brake fluid
cast as part of the housing or added as a
removable plastic part
Piston and Cup
Residual
Pressure
Valve
Brakes applied, fluid
flows freely
Brakes released, the
valve closes to restrict
the return of fluid to
the master cylinder
Dual Master Cylinder

Uses two separate hydraulic pistons
and two fluid reservoirs
Each piston operates a hydraulic circuit
that controls two wheel brake
assemblies
If there is a leak in one of the hydraulic
circuits, the other circuit can still
provide braking action on two wheels
Dual
Master
Cylinder

(Normal Operation)
Both pistons produce pressure to all four

wheel brake assemblies

(Rear Brake Circuit Leak)
Primary piston pushes on the secondary piston,

two wheel brake assemblies still work

(Front Brake Circuit Leak)
Secondary piston slides forward, primary piston

operates two wheel brakes normally
Power Brakes
Use a booster and vacuum or hydraulic
pressure to assist brake pedal
application
The booster is located between the
brake pedal linkage and the master
cylinder
When the driver presses on the brake
pedal, the brake booster helps push on
the master cylinder pistons
Vacuum Booster
Uses vacuum produced in the engine
intake manifold or by a separate pump
to apply the hydraulic brake system
Consists of a housing that encloses a
diaphragm
When vacuum is applied to one side of
the booster, the diaphragm moves
toward the low-pressure area
Vacuum
Booster
Operation
Atmospheric
Suspended Brake
Booster
Atmospheric pressure is present on
both sides of the diaphragm when the
brakes are released
When the brakes are applied, vacuum
is routed to one side of the booster
Atmospheric pressure then pushes on
and moves the diaphragm
Vacuum Suspended
Brake Booster
Vacuum is present on both sides of the
diaphragm when the brakes are
released
When the brakes are applied, vacuum
is released from one side of the booster
Atmospheric pressure then pushes on
and moves the diaphragm
Vacuum Brake Booster
Hydraulic Booster
Uses power steering pump pressure to
help the driver apply the brake pedal
Known as hydro-boost or hydra-booster
Commonly used on vehicles with diesel
engines
diesel engines do not produce a usable
amount of intake manifold vacuum
Hydraulic Booster
Hydraulic Booster
When the pedal pushes on the unit, the spool

valve allows more oil to enter the pressure
chamber, pushing on the power piston
Brake Fluid
Specially blended hydraulic fluid that
transfers pressure to the wheel brake
assemblies
Rated by the SAE and DOT
SAE (Society of Automotive Engineers)
DOT (Department of Transportation)
Brake Fluid
Brake fluid must have the following
characteristics:
correct viscosity at all temperatures
high boiling point
noncorrosive
water tolerant
lubricates components
low freezing point
Brake Lines and Hoses

Transfer fluid pressure from the master
cylinder to the wheel brake assemblies
Lines
made of double-wall steel tubing
tubing ends usually have double-lap flares
Hoses
made of reinforced rubber
used where flexing action is necessary
Brake Lines and Hoses
Brake Line Hardware

Brackets and clips
secure the hoses
and lines to prevent
damage
Brake
Systems
Often used on rearwheel-drive vehicles
Often used on frontwheel-drive vehicles,

with high front-to-rear
brake ratio
Disc Brake Assembly
The assembly consists of a caliper, brake

pads, a rotor, and hardware
Single-Piston Caliper
The caliper slides, as the piston moves in to

clamp the brake pads against the rotor
Fixed Caliper
The caliper remains stationary, as pistons

on each side clamp the rotor
Brake Caliper
Assembly
Caliper Components
Piston seal
prevents pressure leakage between the
piston and the cylinder
helps pull the piston back into the cylinder
when the brakes are not applied
Boot
prevents road dirt and water entry
Bleeder screw
allows air to be removed from the system
Caliper Operation
When the brakes are applied, brake
fluid flows into the caliper cylinder
Fluid pressure pushes the piston
outward, forcing the brake pads into the
rotor
When the brakes are released, the
stretched piston seal pulls the piston
back into the bore, as fluid pressure
drops
Caliper Operation
Brakes applied
Brakes released
Disc Brake Pads

Steel plates to which linings are riveted
Linings
made of heat-resistant organic or
semimetallic friction material
semimetallic linings withstand higher
temperatures without losing their frictional
properties
Disc Brake Pads

Anti-rattle clips
keep the brake pads from vibrating and
rattling
Pad-wear sensor
metal tab on the brake pad
emits a loud squeal when it scrapes
against the brake disc, which happens
when the lining has worn too thin
Brake Disc (Rotor)

Uses friction from the brake pads to
slow or stop wheel rotation
Normally made of cast iron
Constructed as part of the hub or as a
separate unit
Can be solid or have a ventilated rib
construction
Disc Brake Assembly
This rotor is vented to increase cooling

Floating Caliper
The disc brake is mounted on two bolts
supported by rubber bushings
Uses one piston
The caliper is free to shift, or float, in
the rubber bushings
Sliding Caliper
Uses one piston
Mounted in slots machined in the
caliper adapter
The caliper is free to slide sideways in
the slots as the linings wear
Fixed Caliper
Uses more than one piston and caliper
cylinder
The caliper is bolted directly to the
steering knuckle
Pistons on both sides of the disc push
against the brake pads
Drum Brake Assembly
A large drum surrounds the brake shoes

and the hydraulic wheel cylinder
Backing Plate
Holds the springs, wheel cylinder, and
other parts inside the drum
Helps keep road dirt and water off the
brakes
Bolts to the axle housing or the spindle
support
Wheel Cylinder
Assembly
Uses master cylinder pressure to force the

brake shoes out against the drum
Wheel Cylinder
Components
Boots
keep road dirt and water out of the cylinder
Pistons
metal or plastic plungers that transfer force
out of the cylinder to the brake shoes
Cups
rubber seals that keep fluid from leaking
past the pistons
Wheel Cylinder
Components
Springs
hold the rubber cups against the pistons
when the wheel cylinder assembly is not
pressurized
metal expanders may be used on the ends
Bleeder screw
provides a means of removing air from the
brake system
Brake Shoes
Rub against the revolving brake drum to
produce braking action
Made by fastening organic friction material
onto a metal shoe
rivets or bonding agents may be used
The front shoe is the primary shoe

uses the shorter lining
The rear shoe is the secondary shoe

uses the larger lining surface area
Brake Shoes
Retracting springs
pull the brake shoes away from the brake
drums when the brake pedal is released
Hold-down springs
hold the brake shoes against the backing
plate when the brakes are in the released
position
Drum Brake Assembly
Brake Shoe Adjusters

Maintain the correct drum-to-lining clearance
as the brake linings wear
Automatic adjusters normally function when
the brakes are applied with the vehicle
moving in reverse
If there is too much lining clearance, the
brake shoes move outward and rotate with
the drum enough to operate the adjusting
lever
Cable-type star wheel adjuster

Link-type star wheel adjuster

Lever-type star wheel adjuster

Cable-type star wheel adjuster with

an overtravel spring
Lever-latch adjuster
Sliding-latch adjuster
Brake Drums
Provide a rubbing surface for

the brake shoe linings
Brake Shoe
Energization
When the brake shoes are forced
against the rotating drum, they are
pulled away from their pivot point by
friction
This self-energizing action draws the
shoes tighter against the drum
Servo action results when the primary
shoe helps apply the secondary shoe
Brake Shoe
Energization
Self-Energizing Action
Primary shoe is self-energized
Servo Action
Less hydraulic pressure is
needed to apply the brakes
Control Valves and

Switches
Stoplight Switch
Operates the rear brake lights
Normally open switch, usually mounted
on the brake pedal mechanism
When the brake pedal is pressed, it
closes the switch
Brake Warning Light

Switch
Also called the pressure differential
valve
Warns the driver of a pressure loss on
one side of a dual brake system
If a leak develops in either the primary
or secondary brake system, unequal
pressure pushes the switch piston to
one side, grounding the indicator circuit
Brake Warning Light

Circuit
Brake Warning Light

Switch
Pressure difference pushes the piston to

close the warning lamp circuit
Low-Fluid Warning
Light Switch
Turns on a dash light if the brake fluid
in the master cylinder becomes low
Often mounts in the master cylinder lid
or cover
Commonly operated by a float
Metering Valve
Used to equalize braking action on vehicles
with front-wheel disc brakes and rear-wheel
drum brakes
Located in the line to the disc brakes
Prevents the front brakes from applying until
pressure reaches approximately 75135 psi
(517930 kPa)
This pressure overcomes the rear brake
return springs
Proportioning Valve
Used to equalize braking action on vehicles
with front-wheel disc brakes and rear-wheel
drum brakes
Located in the line to the drum brakes
Limits pressure at the rear drum brakes
when high pressure is needed to apply the
front disc brakes
Minimizes rear-wheel lockup during heavy
braking
Combination Valve
Single unit that functions as a brake
warning light switch, a metering valve,
and/or a proportioning valve
Common on late-model vehicles
Combination Valve
Master Cylinder
Incorporates a proportioning valve

and a warning light switch
Parking Brake
Operation
When the hand or foot lever is
activated, it pulls a steel cable that runs
through a housing
The cable pulls on a lever inside the
drum or disc brake assembly, forcing
the brake linings against the rear drums
or discs
Parking
Brake
Components
Foot-operated parking
brake pedal
A lever pushes the shoes

against the drum
Parking Brake
Operation
(Rear Disc Brakes)
A thrust screw and a lever can be
added to the brake caliper
When the parking brake is applied, the
cable pulls on the caliper lever
The caliper lever turns the thrust screw,
which pushes on the caliper piston and
applies the brake pads to the disc
Rear Disc Brake

Caliper
Note the parking brake mechanism


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by

The Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Basic brake system

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Drum and Disc Brakes

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Drum and Disc Brakes

Comparison of front wheel braking

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Typical Braking Ratios

Permission granted to reproduce for educational use only

Automotive brakes use a hydraulic

Permission granted to reproduce for educational use only

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Cylinders of different sizes:

Permission granted to reproduce for educational use only

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Hydraulic jack operation

Permission granted to reproduce for educational use only

Hydraulic Brake Action

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Hydraulic Brake Action

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Brake Pedal Assembly

A lever arm to increase the force applied

Permission granted to reproduce for educational use only

Permission granted to reproduce for educational use only

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Permission granted to reproduce for educational use only

Residual pressure valves

Permission granted to reproduce for educational use only

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Piston and Cup

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Dual Master Cylinder

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only