ACKNOWLEDGMENTS
Thank you to those who provided support before and during the production of this book in the form of education, emotional support, writing skills, photos, friendship, and understanding.
First of all, thank you to my wife, Terry, who let me put aside all of my honey-do lists and to the rest of my family and friends who didn’t see a lot of me during the process. Mom, I will get to your lawn soon! Thanks for teaching me life skills and about the love of God.
To my son, Rob, who shares the love of all things automotive with me. I miss all those car shows we frequented when you were young, but I am glad we had the opportunity to build your 1970 Chevelle together when you were a teenager. You always shine with creativity.
To all the NACAT members and the folks at ASE who have supported me at the conventions and workshops.
To Jim Halderman, another author and teacher who I have been friends with for many decades, who I hold with the greatest respect for his unselfish help to me and the entire automotive industry. He will probably never actually retire because he cares too much. Many thanks for supplying some of the photos in this book. You’re the absolute best, Jim!
To Clarence Vollmer who was my Mr. Miyagi at the Ford dealership back in the 1970s when I was an apprentice mechanic. Being on flat rate means that helping others can hurt your paycheck. Mr. Vollmer gave of himself and mentored me through those early days. He showed me the ropes in a way that improved my abilities and gave me confidence.
To Tye Hughes, who took me under his wing when I was starting out in this business and told me I could do it when I was asked to teach a class at Carter Carburetor unexpectedly. He believed in me and pushed me to become an automotive instructor against my wishes, which has been a very rewarding experience for the last 35-plus years.
To Roger Creason, a great friend and teacher and the best man in the alignment business. Thanks for helping me both technically and to become a better educator.
To my good friend Mark Baker, who built a go-cart with me when we were kids and became my boss years later at Federal-Mogul. Also to all those in Mark’s department who helped me: you know who you are. Thanks, guys and gals.
To Randy Wright, Mark Riecks, Dan Smith, Mark Isaac, and others who helped me develop a love of everything mechanical from all the stuff we tore apart over the years and sometimes put back together.
You all deserve a lot more than my thanks because you gave of yourselves. This industry is a just a big family. Thanks for making me feel welcome. It has been quite a ride.
DEDICATION
To my dad, who was taken away from us much too early. He loved all things mechanical and started me on this journey by taking the time to help me fix my bike and tear a lawn mower engine apart. I miss you every day.
INTRODUCTION
Congratulations on doing your own brake job! You have made the decision to learn a new skill or improve an existing one. Doing so will give you the satisfaction of completing an important, very critical task. At the completion, you will know it was done right and you will save some money too. You will also be able to assist your family and friends to help them save some money or maybe even earn some extra money. It is no secret that the brakes on your vehicle cannot be taken lightly and that the proper procedures are critical to your safety and others on the road. The proper procedures are also critical to your safety when working on your brakes. Please read and understand everything before you touch the first bolt or remove the first wheel cover.
This book is divided into 10 chapters. Although each chapter is specific to a particular subject related to brake systems and could be used on its own, you are encouraged to read the entire book before tackling a brake job. The book begins with an overview of brake systems and their history, which is followed by the components that comprise the system.
Following that, specifics about disc brakes, drum brakes, parking brakes, and the hydraulic system are provided. The hydraulic system supplies the force to apply the brakes at the wheels and must be carefully inspected, serviced, and bled during the brake job. Your vehicle uses a brake assist system to increase the force that you apply to the brake pedal. The next chapter covers how that is accomplished: with vacuum, power steering pressure, or electrically. All components, operation, diagnosis, and service steps are included in each of these chapters.
You will also find a chapter on troubleshooting, outlining common brake problems and their causes. Another chapter covers ABS and electronic brake systems. These systems interact with the base brake system you will be working on, so you need to know some details about their operation and precautions related to them. Also included is a glimpse into the future of how brake systems will evolve when ADAS and autonomous vehicles become more common on the road.
In addition to using this book, it is also very important to refer to the factory service information for specific details about the system you are working on. For example, some newer electronically controlled brake systems require that the system be put into service mode prior to repairs. The system has the ability to perform a self-test, which can pressurize the hydraulic system without warning. This could cause injury if the hydraulic system is open or your hands are in a component, such as a brake caliper, during service. Some models have electric parking brakes that may require a special procedure to retract the caliper so new brakes can be installed. In addition to the service manual that is normally available online, a technical service bulletin (TSB) may be available from the manufacturer to explain an update or common issue related to your vehicle.
After reading this book, you will have a good knowledge of automotive and light truck brake systems. With some common tools and a few special ones, brake work could become something you look forward to. The final chapter provides a step-by-step overview to performing a complete brake job on a disc and drum brake vehicle with photos explaining every step. It can be used as an outline after reading the detailed chapters that cover the specifics with greater depth.
Again, congratulations on learning a new skill!
CHAPTER 1
BASIC BRAKE OPERATION
When you come to a stop sign, your vehicle has to be able to stop, and when it comes to safety, brakes are critically important.
Safety
Automobile manufacturers of the 1960s and 1970s boasted seat belts, safety glass, radial tuned suspension, safety cages, radial tires, and crumple zones. Since then, we’ve seen airbags, back-up cameras, and a long list of other safety-related updates. Antilock Brake Systems (ABS) have been around for more than 30 years, and now with the addition of Advanced Driver Assistance Systems (ADAS) and autonomous vehicles with no steering wheels on the horizon, we are moving into a new level of safety. The promise of these systems may completely eliminate vehicle fatalities someday.
Automotive brake systems are obviously important to vehicle safety and must be in excellent working condition, ready to perform in all conditions. Over the years, improvements have been made to greatly enhance driver assistance and comfort. Electronics have made it possible for engineers to blend the brake system into other vehicle systems, but the basic brake system has not changed all that much since its early designs.
Electronics have made this possible and are a big part of our lives and the modern vehicle, but there will always be a need for basic brake maintenance. The friction components are wear items and must be replaced at some point. Unless we jump to hovering vehicles on magnetism, air, or some other means, we will continue to have wheels that must be stopped.
You need to also consider your own safety when working on your vehicle’s brake system. Safety glasses or a face shield, gloves, a dust mask, and ear