Hydraulic Disc Brake Systems Parts Technician First Period Material Identification and Calculations 270103m.

Hydraulic Disc Brake Systems

Parts Technician

First Period

Material Identification and Calculations

270103m

© 2013, Her Majesty the Queen in right of the Province of Alberta

Figure 1 - Major components of a front disc brake system.


Figure 2 - Discs swept area versus similar diameter drum swept area.


Figure 3 - Equal braking force is applied to both sides of the disc.


Figure 4 - Disc mountings.


Figure 5 - Composite discs.


Figure 6 - Solid disc (left) versus vented disc (right).


Figure 7 - Airflow through the rotor.


Figure 8 - Brake pad area versus heat dissipation area.


Figure 9 - Minimum thickness markings.


Figure 10 - A disc micrometer used to measure thickness.


Figure 11 - Check for grooves and ridges.


Figure 12 - Examples of disc damage.


Figure 13 - Disc brake caliper housing.


Figure 14 - An aluminum caliper with fins.


Figure 15 - Caliper clamping forces.


Figure 16 - Fixed calipers.


Figure 17 - Cutaway view of a four-piston fixed caliper.


Figure 18 - Fixed caliper halves showing the O-ring seal and drilled passages.


Figure 19 - Fixed caliper components.


Figure 20 - A single piston and a double piston sliding or floating caliper.


Figure 21 - Caliper mount.


NOTE

The bushings are often supplied with replacement pads. Check the packaging and if the bushings are not included, suggest them as a related sales item. Inform the customer that the caliper must slide freely to operate correctly.


Figure 22 - Sliding calipers components.(Courtesy DaimlerChrysler Corporation)


Figure 23 - Two methods used to retain the floating caliper.


Figure 24 - Floating or sliding caliper.


Figure 25 - Sliding calipers apply force from both sides of the disc in the same fashion as a C-clamp.


Figure 26 - Pistons.


Figure 27 - Exploded view of caliper, seals, bushings and boot.


Figure 28 - Caliper piston seal in the applied and released positions.


Figure 29 - Brake pad.


Figure 30 - Audible pad wear indicator (squealer).


Figure 31 - A sensor imbedded in the pad to provide an input to an electronic warning device on the dash.


Figure 32 - Silencers located on the back of the pad.


Figure 33 - Anti-squeal compound used to reduce brake noise.


Figure 34 - The parking brake foot pedal and a hand lever.


Figure 35 - Graphic symbols used for parking brake and brake warning.


Figure 36 - A complete parking brake set-up.(Courtesy Honda Canada Inc.)


Figure 37 - Parking brake cable construction.


Figure 38 - A drum-in-hat style rear brake system.


Figure 39 - Backing plate and anchor.


Figure 40 - Components found in a drum-in-hat parking brake system.


Figure 41 - The two most common designs of rear calipers.


Figure 42 - Parking brake cable attachment and return spring location.


Table 2 - Common replacement components and related sales.

Failed Component Related Sales

brake disc/rotor wheel bearings seals brake fluid grease

disc brake pads caliper bushings and seals hardware brake quiet brake lubricantgrease

park brake cables levers and struts brake shoes seals wheel bearings grease


NOTE

In most cases, caliper cores must be returned assembled. Some manufacturers also require them to be in the box of the rebuilt caliper.

Hydraulic Disc Brake Systems Parts Technician First Period Material Identification and Calculations 270103m.

Documents

province of albertafigure

floating caliper

disc brake caliper housing

fixed caliper components

piston fixed caliper

aluminum caliper

caliper mount

solid disc