BRAKES QUALITY FRICTION PRODUCTS FROM A NAME YOU TRUST How is the Brake System Evolving? Performing a Proper Diagnosis Latest Repair Techniques and Installation Recommendations • • • A PROFESSIONAL TECHNICIAN’S GUIDE TO BRAKE SERVICE Quality Friction Products from a Name You Trust Brake System Overview Understanding the Safety Triangle ™ Professional Technician’s Recommended Checklist Inspection of Brake Pads Conditions That May Cause Noise Inspection of Brake Pads Overheating Conditions Inspection of Brake Dust Inspection of Brake Pads Normal vs. Excessive Pad Wear Comparisons Inspection of Brake Pads Lack of Proper Lubrication Inspection of Rotor and Hydraulic System Inspection of Brake System Electronics Brake Pads Installation Quick Tips Common Brake Shoe Noise Conditions Brake Shoes Installation Quick Tips A Complete Line of Stopping Solutions The Right Product Support
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BRAKES - AA1Car.com QUALITY FRICTION PRODUCTS FROM A NAME YOU TRUST How is the Brake System Evolving? ... of ceramic forcedpads RUST BRAKE ROTOR OR PAD DUST
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A TECHNICIAN’S GUIDE TO ASSIST WITH DIAGNOSIS AND INSPECTION
Brake PedalPosition Sensors
Yaw Rate Sensor
Steering WheelPosition Sensor
ABS Command Module
Collision Detector Sensors
Metering ValveCombination Valve
Proportioning Valve
DiscBrakes
DrumBrakes
PressureDifferential Switch
Master Cylinder
Brake FluidReservoir
Power Booster
FlexibleHydraulic Lines
Disc Brake RotorBrake Pad
Brake Pads Piston
ShimsPistonBootCaliper
SteelHydraulic Lines
Parking BrakeCable
Return Spring
Brake DrumBacking Plate
Brake FluidBleed Screw
Wheel Cylinder
Lever
Adjuster LeverSpring
PistonSeal
Shoe ShoeAdjusterCaliper
GuidePins
ParkingBrake
BrakePedal
IDENTIFYINGBRAKE SYSTEM COMPONENTS
Quality Friction Productsfrom a Name You Trust
Brake SystemOverview
Understanding theSafety Triangle™
Professional Technician’sRecommended Checklist
Inspection of Brake PadsConditions That
May Cause Noise
Inspection ofBrake Pads
Overheating Conditions
Inspection ofBrake Dust
Inspection of Brake PadsNormal vs. Excessive
Pad Wear Comparisons
Inspection ofBrake Pads
Lack of Proper Lubrication
Inspection of Rotor andHydraulic System
Inspection ofBrake System Electronics
Brake Pads InstallationQuick Tips
Common Brake ShoeNoise Conditions
Brake Shoes InstallationQuick Tips
A Complete Lineof Stopping Solutions
The RightProduct Support
3
UNDERSTANDING THE SAFETY TRIANGLE™
INTERCONNECTED UNDERCAR PARTS THAT AFFECT A DRIVER’S ABILITY TO AVOID ACCIDENTS
STEERINGBrakes work in conjunction withAnti-Lock Brake Systems providingcontrolled steering during hazardousstopping situations.
Brakes in conjunction withStability Control Systems helpimprove vehicle balance and handlingduring evasive maneuvers.
STOPPINGFront and rear brakes work togetherto help your vehicle consistently stopunder various driving conditions.Modern Active Braking Systems can helpyou stop sooner in emergency situations.
STABILITY
WHAT IS THE SAFETY TRIANGLE™ INSPECTION?
The Safety Triangle™ Inspection checks critical interconnected system componentsthat control steering, stopping and stability. Going beyond tires and brakes to include
shocks, struts, springs, tie rod ends, ball joints and a host of other suspension andchassis parts, the Safety Triangle™ is vital to a driver’s ability to avoid accidents.
Just one worn part could diminish vehicle control and compromise safety.
The Safety Triangle™ Inspection is a three-part process duringwhich a professional technician (1) interviews the owner of the
vehicle, (2) evaluates the brake system balance during operation,and (3) physically evaluates the brake system components.
Quality Friction Productsfrom a Name You Trust
Brake SystemOverview
Understanding theSafety Triangle™
Professional Technician’sRecommended Checklist
Inspection of Brake PadsConditions That
May Cause Noise
Inspection ofBrake Pads
Overheating Conditions
Inspection ofBrake Dust
Inspection of Brake PadsNormal vs. Excessive
Pad Wear Comparisons
Inspection ofBrake Pads
Lack of Proper Lubrication
Inspection of Rotor andHydraulic System
Inspection ofBrake System Electronics
Brake Pads InstallationQuick Tips
Common Brake ShoeNoise Conditions
Brake Shoes InstallationQuick Tips
A Complete Lineof Stopping Solutions
The RightProduct Support
4
PROFESSIONAL TECHNICIAN’S RECOMMENDED CHECKLIST
CUSTOMERS EXPECT QUIET, CLEAN, DEPENDABLE AND SAFE BRAKES
TEST DRIVECUSTOMER INTERVIEWHave you experienced any noises while braking?
Excessive brake temperatures“Riding” the brake pedalHigh speed stopsUnbalanced braking effort fromfront-to-rear or side-to-sideFriction material contaminatedwith solvents or greaseHydraulic bindingMechanically bindingLack of down shifting /engine braking on steep gradesImproper friction material selectionfor braking conditions
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Excessively shiny and hardfriction material surfacecan result in glazing andpedal feel issues, likelyresulting in increasedstopping distances
Causes of glazing and uneven,“wavy” rotor surface:
Quality Friction Productsfrom a Name You Trust
Brake SystemOverview
Understanding theSafety Triangle™
Professional Technician’sRecommended Checklist
Inspection of Brake PadsConditions That
May Cause Noise
Inspection ofBrake Pads
Overheating Conditions
Inspection ofBrake Dust
Inspection of Brake PadsNormal vs. Excessive
Pad Wear Comparisons
Inspection ofBrake Pads
Lack of Proper Lubrication
Inspection of Rotor andHydraulic System
Inspection ofBrake System Electronics
Brake Pads InstallationQuick Tips
Common Brake ShoeNoise Conditions
Brake Shoes InstallationQuick Tips
A Complete Lineof Stopping Solutions
The RightProduct Support
7
INSPECTION OF BRAKE DUST
COMMON BRAKE DUST CONDITIONS
BLACKBRAKE PAD DUST
Excessive wearof semi-metallic pads
and rotors
TANBRAKE PAD DUST
Excessive wearof ceramic pads
RUSTBRAKE ROTOR OR PAD DUST
Ferrous metal in brake dustfrom rotors and / or pads
oxidizes on wheels, causingwheel finish to be rust-colored
HEAT = WEAR = DUSTSOLUTION 1)CHECK FOR EQUAL BRAKING EFFORT ON ALL FOUR CORNERS VIA INFRARED THERMOMETER
SOLUTION 2)DUST CAN BE REDUCED BY
ENSURING THE PADSFIT PROPERLY
Visual symptoms include shinyedges, no lubricant, cracks in thepad surface from heat, and glazedfriction material from brake dragIndicates the brake pads wereforced into place, without lubricant
Proper preparation includes cleaningrust from tab contact surface and areasunderneath noise elimination clips
Pads should slide in by hand,with slight drag
Do not force pads into placewith tools such as a hammer,or a rubber mallet
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Quality Friction Productsfrom a Name You Trust
Brake SystemOverview
Understanding theSafety Triangle™
Professional Technician’sRecommended Checklist
Inspection of Brake PadsConditions That
May Cause Noise
Inspection ofBrake Pads
Overheating Conditions
Inspection ofBrake Dust
Inspection of Brake PadsNormal vs. Excessive
Pad Wear Comparisons
Inspection ofBrake Pads
Lack of Proper Lubrication
Inspection of Rotor andHydraulic System
Inspection ofBrake System Electronics
Brake Pads InstallationQuick Tips
Common Brake ShoeNoise Conditions
Brake Shoes InstallationQuick Tips
A Complete Lineof Stopping Solutions
The RightProduct Support
8
NORMAL vs. EXCESSIVE PAD WEAR COMPARISONS
EXCESSIVEInner Pad Wear
Causes:
NORMALFull Life Pad Wear
Even wear on both the innerand outer pad
If both wheel sets are in thiscondition, then brake systemis functioning normally andpads have run their useful life
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NORMALPad Wear
Even wear on both the innerand outer pad
If both wheel sets are in thiscondition, then brake systemis functioning normally
Technician should continuewith M.A.P. preventativemaintenance schedule
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EXCESSIVETapered Pad Wear
Causes:
EXCESSIVEOuter Pad Wear
Causes:
INSPECTION OF BRAKE PADS
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Seized piston, pin or bushings
Limited movement of caliper;seized or not lubricated
Installation hardware and / orbushings not lubricated
• Binding of caliper usuallyfrom contamination orlack of lubrication oncaliper slides / pins
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Rust near installation hardwarebinds pad
Limited movement of caliper;seized or not lubricated
Installation hardware and / orbushings not lubricated
Quality Friction Productsfrom a Name You Trust
Brake SystemOverview
Understanding theSafety Triangle™
Professional Technician’sRecommended Checklist
Inspection of Brake PadsConditions That
May Cause Noise
Inspection ofBrake Pads
Overheating Conditions
Inspection ofBrake Dust
Inspection of Brake PadsNormal vs. Excessive
Pad Wear Comparisons
Inspection ofBrake Pads
Lack of Proper Lubrication
Inspection of Rotor andHydraulic System
Inspection ofBrake System Electronics
Brake Pads InstallationQuick Tips
Common Brake ShoeNoise Conditions
Brake Shoes InstallationQuick Tips
A Complete Lineof Stopping Solutions
The RightProduct Support
LACK OF LUBRICANTBacking Plate / ShimShows Circular Wearfrom Piston Contact
Lubricate all pad-to-calipercontact areas, including:
Backing plate / shim, piston, tabs,spring clips and abutment area.
OVER-LUBRICATED /CONTAMINATION
Pad SurfaceLooks Greasy or Shiny
Caused by friction materialcontaminated with grease.
To resolve, use warm water and cleardetergent to clean friction material.
Make sure to handle new pads only withclean material during installation. 9
INSPECTION OF BRAKE PADS
LACK OF PROPER LUBRICATION - MAIN CAUSE OF BRAKE NOISE
WHERE TO APPLY LUBRICANTTo avoid rotor contamination, do not apply an excessive amount of lubricant.
Apply an even amount of lubricant to areas of the backing plate that willtouch metal - including the shim and both sides of installation hardware.
Clean and lubricate slide pins on pin-type floating calipers.
Quality Friction Productsfrom a Name You Trust
Brake SystemOverview
Understanding theSafety Triangle™
Professional Technician’sRecommended Checklist
Inspection of Brake PadsConditions That
May Cause Noise
Inspection ofBrake Pads
Overheating Conditions
Inspection ofBrake Dust
Inspection of Brake PadsNormal vs. Excessive
Pad Wear Comparisons
Inspection ofBrake Pads
Lack of Proper Lubrication
Inspection of Rotor andHydraulic System
Inspection ofBrake System Electronics
Brake Pads InstallationQuick Tips
Common Brake ShoeNoise Conditions
Brake Shoes InstallationQuick Tips
A Complete Lineof Stopping Solutions
The RightProduct Support
10
INSPECTION OF ROTOR AND HYDRAULIC SYSTEM
PEDAL FEEL CONCERNS: PULSATION, SPONGY, LOW / HIGH AND HARD PEDAL
CHECK HYDRAULIC SYSTEM
CHECK FOR ROTOR RUN-OUTMake sure hub surface is clean before mountingthe rotor
Solution:Apply vehicle manufacturer’s torque specsto lug nuts following recommended star pattern
Use a dial indicator to measure rotor run-out
Resolve excessive run-out by indexing rotor(Rotate 180º and re-check)
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ROTOR THICKNESS VARIATIONThickness variation is also called “parallelism”
Both sides of the rotor must be parallelto prevent pedal pulsations
Use a caliper to measure rotor thickness infour to twelve locations around the rotor’scircumference
Usually indicates scalloping of the rotor
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For leaks
For torn dust boots
Condition ofrubber hoses
Hydraulic issues can lead to uneven brakepad wear, pedal feel, noise and dust issues
Inspect:
Bleed air from hydraulic system
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Electronic bleeding is recommended on mostmodern systems
High points may require bleedingthrough line connections to completelyeliminate air from the system
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Condition of steel brake lines
For binding calipersand wheel cylinders(Open bleeder to determineif binding is due to internalhose damage)
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Quality Friction Productsfrom a Name You Trust
Brake SystemOverview
Understanding theSafety Triangle™
Professional Technician’sRecommended Checklist
Inspection of Brake PadsConditions That
May Cause Noise
Inspection ofBrake Pads
Overheating Conditions
Inspection ofBrake Dust
Inspection of Brake PadsNormal vs. Excessive
Pad Wear Comparisons
Inspection ofBrake Pads
Lack of Proper Lubrication
Inspection of Rotor andHydraulic System
Inspection ofBrake System Electronics
Brake Pads InstallationQuick Tips
Common Brake ShoeNoise Conditions
Brake Shoes InstallationQuick Tips
A Complete Lineof Stopping Solutions
The RightProduct Support
GRAPHING OFWHEEL SPEED SENSORThe Wheel Speed Sensor readingsshould be almost identical to eachother with no “drop-outs.”
Look for Wheel Speed Sensors that losetheir signal at a relatively higher speed thanthe others when coming to a complete stop.
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Steering Wheel Position Sensors often needto be recalibrated after steering componentshave been replaced or alignment work hasbeen performed.
If the Steering Wheel Position Sensoris out of calibration it can affect thestability control operation.
1) Inspect ABS fuses and relays
2) Perform voltage drop tests on grounds and power
WHAT TO INSPECT?Advanced electronics including active braking /collision avoidance are becoming more integrated intothe operation of the brake system, making it critical to inspectand repair any electrical issues.
• Ensure steering angle position sensor is calibrated
11
INSPECTION OF BRAKE SYSTEM ELECTRONICS
ADVANCED ELECTRONICS
Quality Friction Productsfrom a Name You Trust
Brake SystemOverview
Understanding theSafety Triangle™
Professional Technician’sRecommended Checklist
Inspection of Brake PadsConditions That
May Cause Noise
Inspection ofBrake Pads
Overheating Conditions
Inspection ofBrake Dust
Inspection of Brake PadsNormal vs. Excessive
Pad Wear Comparisons
Inspection ofBrake Pads
Lack of Proper Lubrication
Inspection of Rotor andHydraulic System
Inspection ofBrake System Electronics
Brake Pads InstallationQuick Tips
Common Brake ShoeNoise Conditions
Brake Shoes InstallationQuick Tips
A Complete Lineof Stopping Solutions
The RightProduct Support
BRAKE PADS INSTALLATION QUICK TIPS
HELP DELIVER THE BEST RESULTS AND MINIMIZE COMEBACKS
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4 51 2 3
9 96 7 8
Rotors should be replacedor resurfaced with a fine,
nondirectional finish.
Open bleeder and thencompress piston. Do not
hammer to set pads in place.
Inspect all components.Replace worn hardware,
including pad installation clips.
Check temperature of allfour brakes to ensure
balanced braking effort.
Wash rotor withclear detergent
liquid cleanser and warm water.
Torque lug nuts tomanufacturer specifications
using star pattern.
Do not touch orcontaminate
friction material.
High-speed break-in is NOT recommended!20 - 30 stops, 20 - 30 mph (32 - 48 kph)
leaving 30 seconds between stops.
Lubricate sliding surfaces,back of pad and
both sides of clips.
Quality Friction Productsfrom a Name You Trust
Brake SystemOverview
Understanding theSafety Triangle™
Professional Technician’sRecommended Checklist
Inspection of Brake PadsConditions That
May Cause Noise
Inspection ofBrake Pads
Overheating Conditions
Inspection ofBrake Dust
Inspection of Brake PadsNormal vs. Excessive
Pad Wear Comparisons
Inspection ofBrake Pads
Lack of Proper Lubrication
Inspection of Rotor andHydraulic System
Inspection ofBrake System Electronics
Brake Pads InstallationQuick Tips
Common Brake ShoeNoise Conditions
Brake Shoes InstallationQuick Tips
A Complete Lineof Stopping Solutions
The RightProduct Support
13
COMMON BRAKE SHOE NOISE CONDITIONS
VISIBLE SIGNS OF INSTALLATION ISSUES
NO GAP • NO NOISENormal Operation
Inspect the drum-to-shoe contact area prior to installation.The arc of the brake shoe should match the arc of the drum surface.
A slight clearance at the leading and trailing edges of the frictionmaterial is acceptable, but the center contact should be snug.
CENTER GAP • NOISE ISSUESDrum Brake Groan
When the leading edge of the friction material contactsthe drum surface before the full friction contacts the drum,noise issues occur. Drum brake groan is a loud, low moan
produced at low vehicle speed, with moderate brake pressure.
Quality Friction Productsfrom a Name You Trust
Brake SystemOverview
Understanding theSafety Triangle™
Professional Technician’sRecommended Checklist
Inspection of Brake PadsConditions That
May Cause Noise
Inspection ofBrake Pads
Overheating Conditions
Inspection ofBrake Dust
Inspection of Brake PadsNormal vs. Excessive
Pad Wear Comparisons
Inspection ofBrake Pads
Lack of Proper Lubrication
Inspection of Rotor andHydraulic System
Inspection ofBrake System Electronics
Brake Pads InstallationQuick Tips
Common Brake ShoeNoise Conditions
Brake Shoes InstallationQuick Tips
A Complete Lineof Stopping Solutions
The RightProduct Support
BRAKE SHOES INSTALLATION QUICK TIPS
HELP DELIVER THE BEST RESULTS AND MINIMIZE COMEBACKS
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4 51 2 3
10 11
6
12
7
128 8 9
Inspect the drum forout-of-round and
“bell-mouth” conditions.Drum may be replaced
or remove lip wearby refinishing.
Adjust shoesto drum.
Torque lug nutsusing star pattern.
Clean, inspectand lubricatebacking plate.
Inspect forfrozen or leakingwheel cylinders.
Inspect for leakingaxle seals.
Check temperature of all four brakesto ensure balanced braking effort.
High-speed break-in is NOTrequired or recommended!
Follow manufacturer’srecommendation.
Inspect andclean or replace
hardware, springsand adjuster.
Wash rotor withnon-detergent
(clear) liquid cleanserand warm water.
Do not touch orcontaminate
friction material.
Inspectparking brake
operation.
Press pivot pinsin with vise.
Do NOT use hammerto install pins!
Quality Friction Productsfrom a Name You Trust
Brake SystemOverview
Understanding theSafety Triangle™
Professional Technician’sRecommended Checklist
Inspection of Brake PadsConditions That
May Cause Noise
Inspection ofBrake Pads
Overheating Conditions
Inspection ofBrake Dust
Inspection of Brake PadsNormal vs. Excessive
Pad Wear Comparisons
Inspection ofBrake Pads
Lack of Proper Lubrication
Inspection of Rotor andHydraulic System
Inspection ofBrake System Electronics
Brake Pads InstallationQuick Tips
Common Brake ShoeNoise Conditions
Brake Shoes InstallationQuick Tips
A Complete Lineof Stopping Solutions
The RightProduct Support
15
A COMPLETE LINE OF STOPPING SOLUTIONS
QUALITY BRAKES FROM A NAME YOU TRUST
CERAMICAND SEMI-METALLIC
FRICTION FORMULATIONS
PERFORMANCE-VERIFIEDFRICTION FORMULATIONS
BRAKE SHOES
BRAKE SHOESENGINEERED TO MATCH
OE SPECIFICATIONS
ENGINEERED FORHARD-WORKING TRUCKS,EMERGENCY, SEVERE USE
AND FLEET VEHICLES
U LT R A - P R E M I U M P R E M I U M
Quality Friction Productsfrom a Name You Trust
Brake SystemOverview
Understanding theSafety Triangle™
Professional Technician’sRecommended Checklist
Inspection of Brake PadsConditions That
May Cause Noise
Inspection ofBrake Pads
Overheating Conditions
Inspection ofBrake Dust
Inspection of Brake PadsNormal vs. Excessive
Pad Wear Comparisons
Inspection ofBrake Pads
Lack of Proper Lubrication
Inspection of Rotor andHydraulic System
Inspection ofBrake System Electronics
Brake Pads InstallationQuick Tips
Common Brake ShoeNoise Conditions
Brake Shoes InstallationQuick Tips
A Complete Lineof Stopping Solutions
The RightProduct Support
THE RIGHT PRODUCT SUPPORT
For more information visit: www.monroebrakes.com
Monroe Brakes’ ASE-certified Technical Support Team will help you with answersto the most frequently-asked application, installation and friction questions.
Learn more about your coverage solution for today’s vehiclesFor technical assistance (for trade use only):
1 (800) 201-6506 M - F, 8:30 am - 5:30 pm EST
Monroe Brakes® Technical Support providesinvaluable brake pad technical traininginformation, as well as drum anddisc brakes training information.
If you are looking for answers to technicalquestions, the Monroe Brakes® CustomerService Department is just a phone call away.
FIND ANSWERS TO THE MOSTFREQUENTLY ASKED PRODUCTAND INSTALLATION QUESTIONS
TRAINING CLINICS•
Informative reference material identifying symptomsof brakes failure and corrective diagnostics.
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INFORMATIVE PRODUCT CATALOGSMaximize sales with accurate, industry-leadingpublications and convenient e-catalog.
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IN-DEPTH EDUCATIONAL PROGRAMS HELP SERVICE PROVIDERS RESOLVE FRICTION PROBLEMS