Automotive Brakes Fundamentals (II) Hours 60

In this course the student will learn to diagnose and repair drum and disc brake systems. Also covered will be diagnosing and repairing the entire hydraulic brake system, which will include, the master cylinder, lines and proportioning valves and stop light operation. Students will learn to diagnose and repair power assist units. Finally this course will cover diagnosis and service of wheel bearings, to include how to replace bearings and races, as well as clean, repack and adjust wheel bearing. 


Competencies:

Hydraulic System Diagnosis and Repair 
Diagnose pressure concerns in the brake system using hydraulic principles (Pascal’s Law)
Measure and adjust pedal height. 
Check master cylinder for internal and external leaks and proper operation; determine necessary action. 
Remove, bench bleed, and reinstall master cylinder. 
Diagnose poor stopping, pulling or dragging concerns caused by problems in the hydraulic system; determine necessary action.
Fabricate and install brake lines (double flare and ISO types); replace hoses, fittings, and supports as needed. 
Inspect, test, and replace metering (hold-off), proportioning (balance), pressure differential, and combination valves. 
Inspect, test, replace, and adjust height (load) sensing proportioning valve. 
Inspect, test, and replace components of brake warning light system. 

Drum Brake Diagnosis and Repair 
Diagnose poor stopping, noise, pulling, grabbing, dragging or pedal pulsation concerns; determine necessary action. 
Mount brake drum on lathe; machine braking surface. 
Remove, inspect, and install wheel cylinders. 
Install wheel, torque lug nuts, and make final checks and adjustments. 

Disc Brake Diagnosis and Repair 
Diagnose poor stopping, noise, pulling, grabbing, dragging or pedal pulsation concerns; determine necessary action. 
Disassemble and clean caliper assembly; inspect parts for wear, rust, scoring, and damage; replace seal, boot, and damaged or worn parts. 
Remove and install rotor
Refinish rotor on vehicle.
Refinish rotor off vehicle
Adjust calipers with integrated parking brake system. 
Install wheel, torque lug nuts, and make final checks and adjustments. 

Power Assist Units Diagnosis and Repair 
Test pedal free travel with and without engine running; check power assist operation. 
Check vacuum supply (manifold or auxiliary pump) to vacuum-type power booster. 
Inspect the vacuum-type power booster unit for vacuum leaks; inspect the check valve for proper operation; determine necessary action. 
Inspect and test hydraulically assisted power brake system for leaks and proper operation; determine necessary action. 
Measure and adjust master cylinder pushrod length.

Miscellaneous (Wheel Bearings, Parking Brakes, Electrical, Etc.) Diagnosis and Repair 
Diagnose wheel bearing noises, wheel shimmy, and vibration concerns; determine necessary action. 
Remove, clean, inspect, repack, and install wheel bearings and replace seals; install hub and adjust wheel bearings. 
Check operation of brake stop light system; adjust and service as needed. 
Replace wheel bearing and race.