Brake System.pdf

BR-1

BRAKE SYSTEM

Page

PRECAUTIONS

BR-2

TROUBLESHOOTING

BR-2

CHECKS AND ADJUSTMENTS

BR-6

MASTER CYLINDER

BR-10

BRAKE BOOSTER

BR-17

VACUUM PUMP

BR-49

FRONT BRAKE

BR-62

Drum Brake

BR-62

Disc Brake

BR-69

REAR BRAKE

BR-76

Drum Brake

BR-76

Disc Brake

BR-86

Parking Brake

BR-93

LOAD SENSING PROPORTIONING VALVE

(LSPV)

BR-102

BR-2

BRAKE SYSTEM - Precautions, Troubleshooting

PRECAUTIONS

1 . Care must be taken to replace each part properly as it could

affect the performance of the brake system and result in

a driving hazard. Replace the parts with parts of the same

part number or equivalent .

2 . It is very important to keep parts and the area clean when

repairing the brake system .

TROUBLESHOOTING

Problem

Possible cause

Remedy

Page

Low or spongy Linings worn

Replace brake shoes

BR-62, 76

pedal

Leak in brake system

Repair leak

Master cylinder faulty

Repair or replace master cylinder BR-10

Air in brake system

Wheel cylinder faulty

Bleed brake system

Repair wheel cylinder

BR-7

BR-62, 76

Piston seals worn or damaged

Repair brake cylinder

BR-69, 86

Rear brake automatic adjuster faulty

Repair or replace adjuster

BR-62, 76

Brakes drag

Parking brake out of adjustment

Adjust parking brake

BR-9

Binding parking brake wire

Booster push rod out of adjustment

Repair as necessary

Adjust push rod

BR-47

Tension or return spring faulty

Replace spring

BR-62, 76

Brake line restricted

Lining cracked or distorted

Repair as necessary

Replace shoe

BR-69, 86

Wheel cylinder or caliper piston sticking Repair as necessary

BR-69, 8

Adjuster broken

Replace adjuster

BR-62, 7

Master cylinder faulty

Repair or replace master cylinder BR-11

Brakes pull

Tires improperly inflated

Oil or grease on shoes or pads

Inflate tires to proper pressure

Check for cause. Replace shoes or BR-69, 8

Brake shoes distorted, linings worn or

pads

Replace brake shoes

BR-69, 8

glazed

Brake pads distorted, worn or glazed

Replace pads

BR-69,

Drum or disc out of round

Replace drum or disc

BR-62,

Tension or return spring faulty

Replace spring

BR-69,

Wheel cylinder faulty

Repair wheel cylinder

BR-69,

Piston frozen in brake cylinder

Repair cylinder

BR-62,

Brake pad sticking

Replace pads

BR-62,

BRAKE SYSTEM - Troubleshooting

BR-3

TROUBLESHOOTING (Cont'd)

Problem

Possible cause

Remedy

Page

d pedal but

kes

efficient

Oil or grease on linings

Check for cause. Replace shoes

\ or pads

BR-62, 76

Brake shoes distorted, linings worn

or glazed, drums worn

Replace brake shoes

BR-69, 86

Brake pads distorted, worn or glazed

Replace pads

BR-69, 86

Piston frozen in brake cylinder

Repair cylinder

BR-69, 86

Brake booster faulty

Repair booster

BR-17

Vacuum leaks

Repair as necessary

Vacuum pump faulty

Repair or replace vacuum pump

BR-49

Brake line restricted

Repair as necessary

Snapping or

clicking noise

when

are applied

(Drum brake)

Brake shoes binding at backing plate

ledges

Lubricate

BR-62, 76

Backing plate ledges worn

Replace and lubricate ledges

BR-62, 76

Loose or missing shoe hold-down spring

Replace shoe hold-down spring

Loose set bolt at backing plate

Tighten

BR-62, 76

(Disk brake)

Loose or missing pad support plate

Replace pad support plate

BR-69, 86

Loose installation bolt

Tighten

BR-69, 86

Wear on slide bushing

Replace slide bushing

BR-69, 86

Scraping or

Worn brake linings or pads

Replace or refinish drums or rotors BR-62, 76

grinding noise

if heavily scored

when brakes

Caliper to wheel or rotor interference

Replace as required

BR-69, 86

are applied

Dust cover to rotor or backing plate to

Correct or replace

BR-62, 76

drum interference

Other brake system components faulty

Repair or replace as necessary

Tires rubbing against chassis and/or body

Repair as necessary

BR- 4

BRAKE SYSTEM - Troubleshooting

TROUBLESHOOTING (Cont'd)

Problem

Possible cause

Remedy

Page

Squeaking,

Brake drums and linings, rotors and pads Inspect, repair or replace

BR-62, 76

squealing

groaning or

chattering noise

when brakes

are applied

HINT: Brake

worn or scored

Dirty, greased, contaminated or glazed

linings or pads

Improper linings or pads using

Clean or replace

Inspect for correct usage or

replace

Maladjustment of brake pedal or booster Inspect and adjust

BR-6, 47

friction materi-

push rod

(Disc brake)

Missing or damaged brake pad anti-squeal Replace

als inherently

generate noise

and heat in ord-

BR-69, 86

er to dissipate

energy . As a

result, occa-

shim

Pad wear and pad wear indicator making Replace

BR-69, 86

sional squeal is

normal and is

contact with the rotor

Burred or rusted calipers

Clean or deburr

BR-69, 86

aggravated by

severe environ-

mental condi-

(Drum brake)

Weak damaged or incorrect shoe hold-

Inspect, repair or replace

BR-62, 76

tions such as down springs, loose or damaged shoe

cold, heat, wet-

ness, snow,

salt, mud, etc .

This occasional

squeal is not a

functional

problem and

does not indi-

cate any loss of

brake effec-

tiveness

hold-down spring pins and springs and

grooved backing plate ledges

Squealing and Maladjustment of brake pedal or booster Inspect and adjust

BR-6, 47

squeaking noise

when brakes

push rod

Poor return of brake booster or master

Inspect, repair or replace

BR-10, 17

are not applied

cylinder or wheel cylinder

(Disc brake)

Rusted or stuck piston

Inspect and lubricate as necessary BR-69,86

Improper positioning of pad in caliper

Reinstall correctly

BR-69, 86

Rotor rubbing against caliper housing

Inspect and replace

BR-69, 86

Improper installation of disc brake pad

Reinstall correctly

BR-69, 86

support plate

Pad wear and pad wear indicator making Replace

BR-69, 86

contact with the rotor

(Drum brake)

Weak, damaged or incorrect shoe hold-

Replace

BR-62, 76

down springs

Grooved backing plate ledges

Replace

BR-62, 76

Bent or warped backing plate causing

interference with drum

Improper machining of drum causing

Repair or replace

Replace drum

BR-62, 7

interference with backing plate or shoe

Other brake system components :

Inspect, repair or replace as

BR-62, 7

Loose or extra parts in brakes

necessary

Rear drum adjustment too tight causing

lining to glaze

Worn, damaged or insufficiently lubri-

cated wheel bearings

BRAKE SYSTEM - Troubleshooting

BR- 5

TROUBLESHOOTING (Cont'd)

Problem

Possible cause

Remedy

Page

Groaning, click-

ing or rattling

noise when

brakes are not

applied

Stones or foreign material trapped inside

wheel covers

Remove foreign material

Loose wheel nuts

Tighten to correct torque

Replace if stud holes are

elongated

Maladjustment of brake pedal or booster

Inspect and adjust

BR-6, 47

push rod

Worn, damaged or dry wheel bearings

Inspect and lubricate or replace

(Disc brake)

Loose or missing anti-rattle spring or pad

Inspect, repair or replace

BR-69, 86

support plate or crimping on outer pad

Failure of shim

Inspect, replace if necessary

BR-69, 86

Wear on slide bushing

Inspect, replace if necessary

BR-69, 86

Loose installation bolt

Inspect, tighten if necessary

BR-69, 86

Poor return of piston

Inspect, repair or replace

BR-69, 86

(Drum brake)

Loose or extra parts

Inspect and repair

BR-62, 76

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