Brake System Diagnosis and Repair

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

Tinley Park, Illinois
Goodheart-Willcox Co., Inc.
Permission granted to reproduce for educational use only
(11 Topics)
Brake system problem diagnosis

Brake system inspection
Vacuum booster service
Hydraulic booster service
Master cylinder service
Brake system bleeding
Brake line and hose service

Disc brake service
Brake disc (rotor) service
Drum brake service
Parking brake adjustment
Gather information from the customer

or service writer about any symptoms:
smells, abnormal brake pedal
movements, or improper braking action
Road test the vehicle if necessary

Perform a brake inspection
Decide what adjustments or repairs are
needed
On-Board Diagnostics
Self-diagnostics may be available on
vehicles, especially those equipped
with anti-lock brake systems
Connect a scan tool to the diagnostic
connector
Read any stored diagnostic trouble
codes
Check the scan data for anti-lock brake
operating values
Brake Vibration
Shows up as a chatter, pulsation, or
shake in the brake pedal or steering
wheel
Occurs only when the brakes are
applied
Front brake problems may be felt
mostly in the steering wheel
Pulsation in the brake pedal may be
caused by brake problems at any wheel
Brake Vibration
Possible causes:
warped disc
out-of-round brake drum
hard spots on the disc or drum
Grabbing Brakes
Brakes apply too quickly, even with
light brake pedal application
Possible causes:
malfunctioning brake booster
brake fluid or grease on the linings
worn brake linings
faulty metering valve
mechanical problem in the wheel brake
assembly
Excessive Pedal Effort

Noticeable increase in the amount of
foot pressure needed to apply the
brakes
Possible causes:
seized wheel cylinder or caliper piston
collapsed brake hose or crimped line
faulty master cylinder
contaminated linings
disconnected brake booster vacuum line
or defective booster
Pulling Brakes
The vehicle veers to the right or left
when the brakes are applied
Possible causes:
seized caliper or wheel cylinder piston
grease or fluid-coated lining
leaking cylinder
faulty automatic adjuster
brake lining dust in a drum brake
assembly
Spongy Brake Pedal

The brakes will apply, but the pedal
does not feel solid
Possible causes:
air in the brake system
faulty residual check valve in the master
cylinder
maladjusted brake shoes
Dropping Brake Pedal

The pedal slowly moves all the way to
the floor when steady pressure is
applied to it
Pumping usually restores pedal height
momentarily
Possible causes:
internal leak in the master cylinder
external fluid leak in any component
Low Brake Pedal

The pedal travels too far toward the
floor before braking
Possible causes:
inoperative brake adjusters
maladjusted master cylinder push rod
mechanical problem in the wheel brake
assemblies
Dragging Brakes
The brakes remain partially applied
when the brake pedal is released
To detect dragging brakes, carefully
feel each brake assembly
dragging brakes will be abnormally hot
Dragging Brakes
Possible causes:
seized wheel cylinder pistons or parking
brake cables
overadjusted parking brake or master
cylinder push rod
weak return springs
master cylinder problems
No Brake Pedal
Very dangerous condition in which the
brake pedal moves to the floor with no
braking action
Possible causes:
hydraulic system leak that causes the
loss of the brake fluid
faulty master cylinder
A complete loss of braking is unlikely

on a system with a dual master cylinder
Brake Warning
Light On
Indicates either an internal leak
(master cylinder) or an external leak
Unequal pressure in the dual master
cylinder system has caused the
warning light switch to shift to one side
Braking Noise
Noises include grinding sounds,
squeaks, or rattles
Metal-on-metal grinding sound when
braking
caused by worn brake linings
Braking Noise
Squeak when braking
caused by glazed or hardened brake
linings, dry brake drum backing plate, or
wear indicator rubbing on the rotor
Rattles
caused by a missing anti-rattle clip or
loose parts
Most manufacturers recommend a

periodic inspection of the brake system
When inspecting the brake system,
check the brake pedal action, fluid
level, and the condition of the brake
lines, hoses, and wheel brake
assemblies
Brake System
Problems
Checking Brake Pedal

Action
Apply the brake pedal and compare the
movement to specifications
Brake pedal application specs:
pedal height
pedal free play
pedal reserve distance
Brake Pedal
Measurements
Brake Pedal
Measurements
Using a yardstick to measure the distance

from the steering wheel to the brake pedal
Checking Brake Fluid

Remove the master cylinder cover or
view the level through the side of the
plastic reservoir on some models
Typically, the brake fluid level should
be 1/4" (6 mm) from the top of the
reservoir
Checking Brake Fluid
Checking for Leaks

Inspect for leaks whenever the fluid
level in the master cylinder is low
Check brake lines, hoses, calipers, and
wheel cylinders
Check below the master cylinder
mounting point at the cowl or booster
Leaks show up as darkened, damp
areas
Checking the Parking

Brake
Apply the parking brake
The pedal or lever should not move
more than 2/3 of full travel
The parking brake should keep the
vehicle from moving with the engine
idling and the transmission in drive
Inspect the cables for fraying and high
friction
Checking Wheel Brake

Assemblies
Raise the car on a lift or jack stands
Remove one front wheel and one rear
wheel
Inspect the disc brake assemblies
Inspect the drum brake assemblies
Disc Brake Inspection
Inspect the brake pad linings (minimum

thickness 1/8" or 3 mm)
Inspect the rotors for scoring or heat

damage
Drum Brake Inspection

Remove the brake drums
The brake shoe linings should be at
least 1/16" (1.5 mm) thick
Check the linings for glazing or
contamination from brake fluid or
differential oil
Drum Brake Inspection
Check the drum A badly scored

for cracks or heat drum must be
machined
damage
Inspect the brake booster and the

vacuum hose
hoses may collapse or harden
To test the booster, pump the brake

pedal to remove any vacuum
Apply the brake and start the engine
the pedal should drop slightly as engine
manifold vacuum develops
Removing the Booster
Vacuum Brake Booster
Rebuilding the Booster

Following the service manual
procedures, replace the diaphragm, the
valves, and other plastic or rubber parts
Most boosters are rebuilt by specialty
shops
Hydraulic Booster
Service
Check all the hydraulic lines for signs
of leakage
If the booster is inoperative, check the
power steering fluid level
Most boosters are not serviceable
without special equipment and
procedures
A faulty master cylinder may leak fluid

past the rear piston or leak internally
Inspect for external leakage where the
master cylinder mounts to the booster
or cowl
Internal leakage will cause the pedal to
slowly sink to the floor when applied
Master Cylinder
Removal
Disconnect the brake lines using a line
wrench
Unbolt the master cylinder from the
booster or cowl
On a vehicle without a power-assist
booster, disconnect the push rod from
the brake pedal assembly
Master Cylinder
Rebuild
Following the service manual
procedures, drain the fluid and
disassemble the unit
Honing may be used to remove minor
corrosion or pits from the cylinder
surface must be in perfect condition
Measure piston-to-cylinder clearance

Inspect each component and replace
all cups and seals
Master Cylinder
Rebuild
Clean and lubricate the components with

brake fluid and reassemble the unit
Bench Bleeding
Removes air from inside the

master cylinder
Installing a Master
Cylinder
Bolt the master cylinder to the cowl or
booster
Check the adjustment of the push rod if
specified
Install the brake lines with the fittings
lightly tightened
Installing a Master
Cylinder
Bleed the air from the fittings
Tighten the fittings
Fill the reservoir with fluid
Check brake pedal feel and road test
the vehicle
Air in the brake system will compress,

causing a spongy brake pedal
Bleeding involves the use of fluid
pressure to force air out of the brake
system bleeder screws
Two methods are used:
manual bleeding
pressure bleeding
Manual Bleeding
Attach one end of a hose to a bleeder
screw and place the other end in a jar
containing brake fluid
Have another technician apply light
foot pressure on the brake pedal
Open the bleeder screw while watching
for air bubbles flowing from the hose
Manual Bleeding
Close the bleeder screw
Have your helper release the brake
pedal
Repeat the steps until the flow from the
hose is clear and free of bubbles
Perform the operation on all of the
brake assemblies, starting farthest
from the master cylinder
Manual Bleeding
Pressure Bleeding
Uses a pressure bleeder tank, which

contains brake fluid under pressure
Pressure Bleeding
Fill the tank with fluid
Charge the tank with 1015 psi (69103 kPa)
of air pressure
Fill the master cylinder with fluid
Install the adapter and hose on the master
cylinder
Open the valve in the hose
Pressure Bleeding
Attach one end of a hose to a bleeder
screw and place the other end in a jar
containing brake fluid
Open the screw until the fluid entering
the jar is clear of bubbles
Pressure Bleeding
Repeat the steps on the other wheel

brake assemblies
Flushing a Brake
System
Extends the life of the brake system
components
Done by pressure bleeding all the old
fluid out of the system
Removes contamination such as dirt,
rust, corrosion, oil, or moisture
Bleed each wheel brake assembly until
clean fluid flows from the bleeder screw
Lines are subject to corrosion or

damage
Hoses may deteriorate over time
When replacing brake lines, use
approved double-wall steel tubing
Tools and Procedures
Main steps in disc brake service:

replacing worn brake pads
rebuilding or replacing caliper assemblies
turning (machining) the brake discs
Replacing Brake Pads

Loosen the wheel
lug nuts
Raise the vehicle on
a lift or jack stands
Remove the wheels
Use a large C-clamp to push each piston

back into its cylinder
Unbolt the calipers and slide them

off the discs
Support the calipers to prevent hose

damage and then remove the old pads
Install the anti-rattle clips on the new pads

and fit them into the calipers

Slide the caliper assemblies over the
discs
Assemble the mounting hardware
Make sure all bolts are torqued to
specs
Install the wheel and tighten the lug
nuts to specs
Rebuilding a Caliper
To remove the piston, apply low air
pressure
Pry the old dust boot out of the caliper

Remove the old seal from the caliper

Keep the parts organized

Honing can remove minor imperfections

Lubricate the hone with brake fluid
Inspect the piston for wear or damage
Clean all parts in an approved cleaner
Coat the parts in brake fluid
Work the new seal into the bore groove

Install the new boot in its groove and slide

the piston squarely into the caliper
It is important to check the condition of

the disc
Manufacturers provide specifications
for maximum disc runout and minimum
disc thickness
Measuring Disc
Runout
Runout is the amount of side-to-side
movement measured near the outer
edge of the friction surface
Typical maximum runout:
0.004" (0.10 mm)
If runout is beyond specs, turn the disc

on a brake lathe to true its friction
surfaces
Measuring Disc
Runout
Using a dial indicator, rotate the disc while

watching needle movement
Measuring Disc
Thickness
The thickness will decrease as the disc
wears
The minimum thickness may be printed
on the side of the disc
If the disc thickness is under
specifications, replace the disc
Measuring Disc
Thickness
Using an outside micrometer, measure at

several points around the disc
Resurfacing a Disc
Involves machining a discs friction
surfaces on a brake lathe to correct
runout, thickness variation, or scoring
Mount the disc on the brake lathe
according to the lathe manufacturers
recommendations
With the machine feeds and controls
set properly, machine smooth surfaces
on the disc
Resurfacing a Disc
Always read the
operating manual
before using a brake
lathe
Resurfacing a Disc
Typical rotor mounting on a brake lathe

Resurfacing a Disc
Install a damper to prevent vibration while

machining the rotor
Brake Lathe
This lathe has a large
cover to protect
operators and others
in the shop from
flying debris
On-Car Brake Lathe

Useful on vehicles where the brake
disc is hard to remove or where the
manufacturer specifies on-car rotor
machining
Mounts on the vehicles steering
knuckle
An electric motor turns the disc during
the machining process
On-Car
Brake Lathe
A stand-mounted
electric motor
rotates the disc
On-Car Brake Lathe

The lathe
assembly has
controls for
feeding cutters
into the disc
surface
Disc Brake
Reassembly
After installing the rotor, fit the caliper
assembly into place
High-temperature silicone is used on
the backs of the pads to help prevent
brake rattle and squeal
Apply a small amount of silicone
grease to the caliper mounting bolt
threads
Disc Brake
Reassembly
Disc brake components

Disc Brake
Reassembly
Disc Brake
Reassembly
The rotor and
lining surfaces
should be
perfectly clean
after repairs
Service is needed anytime your

diagnosis finds faulty drum brake
components
Common drum brake faults:
leaking wheel cylinder
worn or contaminated linings
scored drum
seized parking brake components

Spring removal
and adjustment
tools

A brake vacuum is
being used to
prevent inhalation
of brake lining dust
Drum Brake
Disassembly
Drum brake
components
Drum Brake
Disassembly
Remove the wheels and brake drums

and, if necessary, back off the adjuster to
ease the removal of a worn drum
Drum Brake
Disassembly
Use a brake spring

retracting tool to remove
the upper shoe retracting
springs
Use a hold-down
spring tool to remove
the hold-down springs
Drum Brake
Disassembly
Lift the brake shoes off the backing
plate
Remove the automatic adjuster
mechanism
Clean the backing plate
Servicing Wheel
Cylinders
A cylinder must be replaced or rebuilt if
it shows signs of leakage or sticking
Many shops service the wheel
cylinders anytime the linings are
replaced
Wheel cylinder rebuilding involves
honing the cylinder and replacing the
rubber cups and boots
Drum Brake Assembly
Note the wheel cylinder components

Brake Drum
Resurfacing
Needed when the drum is scored, outof-round, or worn unevenly

Mount the drum on the lathe
Wrap a silencing band around the drum
Feed the cutting tool against the inner
surface of the drum
Adjust the depth of the cut to lathe
specs and activate the automatic feed
Brake Drum
Resurfacing
Use the correct
collars and hubs
to secure the
drum to the lathe
shaft
Brake Drum
Resurfacing
This brake lathe has a shoe grinder, which

will arc shoes to fit the drum
Measuring Brake Drum

Diameter
The drum
Typically, a drum
should not be machined diameter is often
stamped on the
more than 0.060"
(1.5 mm) oversize
drum
Use a drum
micrometer to
measure the
diameter
Drum Brake
Reassembly
Clean the wheel bearings
Inspect the bearings for wear or
damage
Pack the bearings with grease and
install new grease seals
Drum Brake
Reassembly
Wipe high-temperature grease on the

raised pads on the backing plate and on
the star wheel threads
Drum Brake
Reassembly
Install the new shoes and the adjuster

mechanism on the backing plate
Preadjusting Drum
Brakes
Ensures proper initial brake system
operation
Fit a brake adjusting gauge into the
brake drum
Set the gauge for the inside diameter
of the drum
Fit the gauge over the brake shoes
Adjust the brake until the linings touch
the gauge
Preadjusting
Drum Brakes
Fitting the gauge into
the brake drum
Adjusting the shoes

Preadjusting Drum
Brakes
Another method of preadjusting the
brakes:
use a brake spoon to turn the star wheel
turn the wheel until the brake drum drags
slightly when rotated by hand
To adjust the parking brake, tighten an

adjustment nut on the cable mechanism
Shorten the cable until the brakes apply
firmly within the first 2/3 of the pedal or
lever travel
Do not overtighten the brake
brakes could drag when released
Parking Brake Cables

Brake System Diagnosis and Repair

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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

Brake system problem diagnosis

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Brake line and hose service

Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Gather information from the customer

Road test the vehicle if necessary

Permission granted to reproduce for educational use only

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

Permission granted to reproduce for educational use only

Excessive Pedal Effort

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Permission granted to reproduce for educational use only

Spongy Brake Pedal

Goodheart-Willcox Co., Inc.

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Dropping Brake Pedal

Goodheart-Willcox Co., Inc.

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Low Brake Pedal

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.

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A complete loss of braking is unlikely

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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

Most manufacturers recommend a

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Goodheart-Willcox Co., Inc.

Permission granted to reproduce for educational use only

Checking Brake Pedal

Goodheart-Willcox Co., Inc.

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Goodheart-Willcox Co., Inc.

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Using a yardstick to measure the distance

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Checking Brake Fluid

Goodheart-Willcox Co., Inc.

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Checking Brake Fluid

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Checking for Leaks

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Checking the Parking

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