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[object Object],[object Object],[object Object],[object Object],[object Object],OBJECTIVES: After studying Chapter 71, the reader should be able to: Continued
[object Object],[object Object],[object Object],OBJECTIVES: After studying Chapter 71, the reader should be able to:
[object Object],KEY TERMS:
BRAKE FLUID  ,[object Object],Continued
[object Object],Figure 71–1  Brake fluid can absorb moisture from the air even through plastic, so many experts recommend that brake fluid be purchased in metal containers. ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
BRAKE FLUID TYPES ,[object Object],Continued ,[object Object],[object Object],[object Object],All polyglycol brake fluid is clear to amber in color .  Brake fluid has to have the following characteristics
BRAKE FLUID SPECIFICATIONS ,[object Object],Continued See the chart on Page 849 of your textbook.
[object Object],[object Object],[object Object],[object Object],Continued
Figure 71–2  Brake fluid absorbs moisture from the air at the rate of about 2% per year. As the brake fluid absorbs water, its boiling temperature decreases. Continued CAUTION:  DOT 3 brake fluid is a very strong solvent and can remove paint! Care is required when working with DOT 3 brake fluid to avoid contact with the vehicle’s painted surfaces. It also takes the color out of leather shoes.
NOTE:   Because brake fluid absorbs moisture over time, many vehicle manufacturers recommend changing the brake fluid as part of the standard services to be performed routinely. The typical recommended brake fluid change interval is every two years or every 30,000 miles (48,000 km), whichever comes first. This is particularly important for vehicles equipped with an antilock braking system (ABS) because of the problem of expensive brake component wear or corrosion caused by contaminated brake fluid.
[object Object],Continued
[object Object],What is Blue Brake Fluid?
[object Object],Continued CAUTION:   Some vehicle manufacturers such as Chrysler do not recommend the use of or the mixing of other types of polyglycol brake fluid and specify the use of DOT 3 brake fluid only. Always follow the vehicle manufacturer’s recommendation.
[object Object],Continued DOT 5 brake fluid is purple (violet) in color to distinguish it from DOT 3 or DOT 4 brake fluid .   Silicones have about three times the amount of dissolved air as glycol fluids (about 15% of dissolved air versus only about 5% for standard glycol brake fluid).  ,[object Object],It is this characteristic of silicone brake fluid that causes the most concern about its use.
[object Object],Continued
[object Object],Continued NOTE:   The characteristics of DOT 5 silicone brake fluid to absorb air is one of the major reasons why it is not recommended for use with an antilock braking system (ABS). In an ABS, valves and pumps are used which can aerate the brake fluid. Brake fluid filled with air bubbles cannot properly lubricate the ABS components and will cause a low, soft brake pedal.
[object Object],[object Object],[object Object],NOTE:   Even though DOT 5 does not normally absorb water, it is still tested using standardized SAE procedures in a humidity chamber. After a fixed amount of time, the brake fluid is measured for boiling point. Since it has had a chance to absorb moisture, the boiling point after this sequence is called the minimum wet boiling point.
HYDRAULIC SYSTEM MINERAL OIL ,[object Object],Continued
[object Object],The Sinking Brake Pedal While driving a four-year-old vehicle on vacation in very hot weather in mountainous country, the brake pedal sank to the floor. When the vehicle was cold, the brakes were fine. But after several brake applications, the pedal became soft and spongy and sank slowly to the floor if pressure was maintained on the brake pedal. Because the brakes were OK when cold, I knew it had to be boiling brake fluid. Old brake fluid (four years old) often has a boiling point under 300°F (150°C). With the air temperature near 100°F (38°C), it does not take much more heat to start boiling the brake fluid.  After bleeding over a quart (1 liter) of new brake fluid through the system, the brakes worked normally. I’ll never again forget to replace the brake fluid as recommended by the vehicle manufacturer. See Figure 71–3 for a tester that can be used to measure the boiling point of brake fluid.
Figure 71–3  A brake fluid tester can test brake fluid for boiling point.
CAUTION:   Mineral hydraulic oil should never be used in a braking system that requires DOT 3 or DOT 4 polyglycol-based brake fluid. If any mineral oil, such as engine oil, transmission oil, or automatic transmission fluid (ATF), gets into a braking system that requires glycol brake fluid, every rubber part in the entire braking system must be replaced. Mineral oil causes the rubber compounds that are used in glycol brake fluid systems to swell, as shown here. Figure 71–4 Both rubber sealing cups were exactly the same size. The cup on the left was exposed to mineral oil. Notice how the seal greatly expanded.
BRAKE FLUID INSPECTION AND TESTING ,[object Object],Continued 1. Proper Level  The brake fluid level should be above the minimum level (labeled MIN) and below the maximum (labeled MAX) on the side of the master cylinder reservoir. Do not add brake fluid unless the entire brake system is carefully inspected for worn brake pads and shoes and for signs of any external leakage. 2. Color/Condition  New brake fluid is clear or amber in color, if the brake fluid is black or discolored it should be changed. See Figures 71-5 and 71-6.
Figure 71–5 New brake fluid is clear or amber in color as shown here. NOTE:   Some experts recommend replacing the brake fluid if it looks like coffee, either black coffee or coffee with cream. Figure 71–6  This brake fluid is black in color and should be replaced. Continued
Figure 71–7  (a) A brake fluid test strip is being used to test the condition of the brake fluid. (b) The color of the test strip is then compared with a chart on the package, which indicates the condition. ,[object Object],Continued
[object Object]
BRAKE FLUID SERVICE PROCEDURES AND PRECAUTIONS ,[object Object],[object Object],[object Object],[object Object],Continued
[object Object],[object Object],Continued NOTE:   To help prevent possible contamination with moisture, air, or other products, purchase brake fluid in small containers. Keep all brake fluid containers tightly closed to prevent air (containing moisture) from being absorbed.
CAUTION:   Alcohol or flushing fluids should not be used because they cannot be totally removed and will contaminate the system. Disassembled parts, however, can and should be cleaned with denatured alcohol or spray brake cleaner where the parts can be visually inspected to be free of cleaning solutions.
[object Object],The Pike’s Peak Brake Inspection I pulled over and asked the inspector what he was checking. He said when linings and drums/rotors get hot, the vehicle loses brake effectiveness. But if the brake fluid boils, the vehicle loses its brakes entirely. The inspector was listening for boiling brake fluid at the front wheel and feeling for heat about 1 ft (30 cm) from the wheel. If the inspector felt heat 1 ft away from the brakes, the brakes were definitely too hot to continue, and you would be instructed to pull over and wait for the brakes to cool. The inspector recommended placing the transmission into a lower gear, which uses the engine to slow the vehicle during the descent without having to rely entirely on the brakes.
BRAKE FLUID HANDLING AND DISPOSAL ,[object Object]
RUBBER TYPES ,[object Object],Continued
Continued See the chart on Page 853 of your textbook.
[object Object],Continued
Figure 71–8  The master cylinder piston seals are usually constructed from EPDM rubber, and the diaphragm of the vacuum power brake booster is usually made from SBR. Figure 71–9  Cross-sectional view of a typical drum brake wheel cylinder. Most wheel cylinder boots and cups are either SBR or EPDM rubber. Continued
Figure 71–10  Exploded view of a typical disc brake caliper. Both the caliper seal and dust boot are constructed of EPDM rubber. Continued
BRAKE LINES ,[object Object],Continued
Figure 71–11 Steel brake tubing is double-walled for strength and plated for corrosion resistance. ,[object Object],CAUTION:   Copper tubing should  never  be used for brake lines. Copper tends to burst at a lower pressure than steel. Continued ,[object Object],[object Object],Double-walled brake tubing is plated with tin, zinc, or other similar substances for protection against rust and corrosion. SAE  J1047  specifies a section of brake line must be able to withstand 8,000 psi.
[object Object],Figure 71–12  Because of the slight difference in flare angle, double-flare fitting seals cause a wedging action. Continued ,[object Object]
[object Object],[object Object],Figure 71–13 An ISO fitting. (also called a  ball flare or  bubble flare ). Continued
Figure 71–14  Double flaring the end of a brake line. (a) Clamp the line at the correct height above the surface of the clamping tool using the shoulder of the insert as a gauge.  ,[object Object],Continued (a)
Figure 71–14 Double flaring the end of a brake line.  (b) The insert is pressed into the end of the tubing. This creates the first bend. (c) Remove the insert and use the pointed tool to complete the overlap double flare. ,[object Object],Continued (b) (c)
Figure 71–14  (d) The completed operation as it appears while still in the clamp.  (e) The end of the line as it appears after the first operation on the left and the completed double flare on the right. ,[object Object],(e) (d) Continued
Figure 71–15  Making an ISO flare requires this special tool. (a) Position the brake line into the two-part tool at the correct height using the gauge end of the tool. (b) Assemble the two blocks of the tool together and clamp in a vise. Turn the tool around and thread it into the tool block. The end of the threaded part of the tool forms the “bubble” or ISO flare. Continued (b) (a)
[object Object],CAUTION:   According to vehicle manufacturers’ recommended procedures, compression fittings should never be used to join two pieces of steel brake line. Only use double-flare ends and connections, if necessary, when replacing damaged steel brake lines. Response time is the amount of time between the pressure increase at the master cylinder and the pressure increase at the brakes . On most vehicles, the brake lines to the front wheels are shorter. Brake engineers size each line to keep the time lag to less than 0.2 second (200 milliseconds). Continued
CAUTION:   The exhaust system near brake lines should be carefully inspected for leaks when diagnosing a “lack of brakes” complaint. Exhaust gasses can hit the brake line going to the rear brakes, causing the brake fluid to boil. Since brake fluid vapors are no longer liquid, they can be compressed, resulting in a total loss of brakes. After the vehicle is stopped and allowed to cool, the brakes often return to normal. Fast response time is critical for the proper operation of the antilock braking system (ABS). As brake fluid ages, its viscosity (resistance to flow) increases, resulting in longer response time. Continued
Figure 71–16  Whenever disconnecting or tightening a brake line, always use the correct size flare nut wrench. A flare nut wrench is also called a tube nut wrench or a line wrench. ,[object Object]
COILED BRAKE LINE ,[object Object],Figure 71–17  The coils in the brake line help prevent cracks caused by vibration. Coils allow movement between brake components without stress that could fatigue metal and cause line breakage.  The master cylinder attaches to the bulkhead of the vehicle; the combination valve often attaches to the frame.  Because body and frame are insulated from each other using rubber isolators, some movement occurs while driving.
ARMORED BRAKE LINE ,[object Object],Figure 71–18  Armored brake line is usually used in the location where the line may be exposed to rock or road debris damage. Even armored brake line can leak and a visual inspection is an important part of any brake service. This armor is designed to prevent damage from stones and debris that dent or damage the brake line.  If a section of armored brake line is to be replaced, armored replacement line should be installed.
[object Object],Bend It Right the First Time - Part 1 Always use a tubing cutter instead of a hacksaw when cutting brake line. A hacksaw will leave a rough and uneven end that will not flare properly except when forming. An ISO flare and a hacksaw is used to provide a rough surface to allow the flaring tool to grip the line during the procedure. Often this means bending the brake line with many angles and turns. To make the job a lot easier, use a stiff length of wire and bend the wire into the exact shape necessary. Then use the wire as a pattern to bend the brake line.
Bend It Right the First Time - Part 2 Figure 71–19 Using a V-belt pulley in a vise to bend brake line. Always use a tubing bender to avoid kinking the brake line. A kink not only restricts the flow of brake fluid, but also weakens the line. To bend brake line without a tubing bender tool, use an old V-belt pulley. Clamp the pulley in a vise, lay the tubing in the groove, and smoothly bend the tubing. Different diameter pulleys will create various radius bends.
FLEXIBLE BRAKE HOSE ,[object Object],Continued Figure 71–20  Flexible brake hoses are used between the frame or body of the vehicle and the wheel brakes. Because of suspension and/or steering movement, these flexible brake lines must be strong enough to handle high brake fluid pressures, yet remain flexible. Note that this flexible brake hose is further protected against road debris with a plastic conduit covering.
[object Object],Figure 71–21 (a) Typical flexible brake hose showing the multiple layers of rubber and fabric. (b) The inside diameter (ID) is printed on the hose (3 mm). Continued (a) (b) CAUTION:   Never allow a disc brake caliper to hang by the flexible brake line. Damage to the line can result. Always use a wire to support the weight of the caliper.
Figure 71–22 Brake hose fabric being woven at the Delco Chassis plant in Dayton, Ohio, USA. ,[object Object],By braiding the yarn, all of the strands operate in tension and, therefore, have great strength to withstand braking system pressure over 1000 psi (6,900 kPa).  Continued
[object Object],Continued
Figure 71–23  All brake hose is carefully inspected and a 3-mm-diameter gauging tool is inserted through the hose to make sure the hose is not restricted. Note the small diameter of the tool compared to the diameter of the hose. Seeing how small the inside diameter of the hose actually is makes it easier to visualize how easy it would be to have a restricted or blocked flexible hose. Continued
Figure 71–24  Typical flexible brake hose faults. Many faults cannot be seen, yet can cause the brakes to remain applied after the brake pedal is released. Continued
Figure 71–25  Flexible brake hose should be carefully inspected for cuts or other damage, especially near sections where the brake hose is attached to the vehicle. Notice the crack and cut hose next to the mounting bracket. ,[object Object]
SUMMARY ,[object Object],[object Object],[object Object],[object Object],[object Object],Continued
SUMMARY ,[object Object],[object Object],[object Object],[object Object],( cont. )
end

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Chap71

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  • 10. Figure 71–2 Brake fluid absorbs moisture from the air at the rate of about 2% per year. As the brake fluid absorbs water, its boiling temperature decreases. Continued CAUTION: DOT 3 brake fluid is a very strong solvent and can remove paint! Care is required when working with DOT 3 brake fluid to avoid contact with the vehicle’s painted surfaces. It also takes the color out of leather shoes.
  • 11. NOTE: Because brake fluid absorbs moisture over time, many vehicle manufacturers recommend changing the brake fluid as part of the standard services to be performed routinely. The typical recommended brake fluid change interval is every two years or every 30,000 miles (48,000 km), whichever comes first. This is particularly important for vehicles equipped with an antilock braking system (ABS) because of the problem of expensive brake component wear or corrosion caused by contaminated brake fluid.
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  • 21. Figure 71–3 A brake fluid tester can test brake fluid for boiling point.
  • 22. CAUTION: Mineral hydraulic oil should never be used in a braking system that requires DOT 3 or DOT 4 polyglycol-based brake fluid. If any mineral oil, such as engine oil, transmission oil, or automatic transmission fluid (ATF), gets into a braking system that requires glycol brake fluid, every rubber part in the entire braking system must be replaced. Mineral oil causes the rubber compounds that are used in glycol brake fluid systems to swell, as shown here. Figure 71–4 Both rubber sealing cups were exactly the same size. The cup on the left was exposed to mineral oil. Notice how the seal greatly expanded.
  • 23.
  • 24. Figure 71–5 New brake fluid is clear or amber in color as shown here. NOTE: Some experts recommend replacing the brake fluid if it looks like coffee, either black coffee or coffee with cream. Figure 71–6 This brake fluid is black in color and should be replaced. Continued
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  • 29. CAUTION: Alcohol or flushing fluids should not be used because they cannot be totally removed and will contaminate the system. Disassembled parts, however, can and should be cleaned with denatured alcohol or spray brake cleaner where the parts can be visually inspected to be free of cleaning solutions.
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  • 33. Continued See the chart on Page 853 of your textbook.
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  • 35. Figure 71–8 The master cylinder piston seals are usually constructed from EPDM rubber, and the diaphragm of the vacuum power brake booster is usually made from SBR. Figure 71–9 Cross-sectional view of a typical drum brake wheel cylinder. Most wheel cylinder boots and cups are either SBR or EPDM rubber. Continued
  • 36. Figure 71–10 Exploded view of a typical disc brake caliper. Both the caliper seal and dust boot are constructed of EPDM rubber. Continued
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  • 44. Figure 71–15 Making an ISO flare requires this special tool. (a) Position the brake line into the two-part tool at the correct height using the gauge end of the tool. (b) Assemble the two blocks of the tool together and clamp in a vise. Turn the tool around and thread it into the tool block. The end of the threaded part of the tool forms the “bubble” or ISO flare. Continued (b) (a)
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  • 46. CAUTION: The exhaust system near brake lines should be carefully inspected for leaks when diagnosing a “lack of brakes” complaint. Exhaust gasses can hit the brake line going to the rear brakes, causing the brake fluid to boil. Since brake fluid vapors are no longer liquid, they can be compressed, resulting in a total loss of brakes. After the vehicle is stopped and allowed to cool, the brakes often return to normal. Fast response time is critical for the proper operation of the antilock braking system (ABS). As brake fluid ages, its viscosity (resistance to flow) increases, resulting in longer response time. Continued
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  • 51. Bend It Right the First Time - Part 2 Figure 71–19 Using a V-belt pulley in a vise to bend brake line. Always use a tubing bender to avoid kinking the brake line. A kink not only restricts the flow of brake fluid, but also weakens the line. To bend brake line without a tubing bender tool, use an old V-belt pulley. Clamp the pulley in a vise, lay the tubing in the groove, and smoothly bend the tubing. Different diameter pulleys will create various radius bends.
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  • 56. Figure 71–23 All brake hose is carefully inspected and a 3-mm-diameter gauging tool is inserted through the hose to make sure the hose is not restricted. Note the small diameter of the tool compared to the diameter of the hose. Seeing how small the inside diameter of the hose actually is makes it easier to visualize how easy it would be to have a restricted or blocked flexible hose. Continued
  • 57. Figure 71–24 Typical flexible brake hose faults. Many faults cannot be seen, yet can cause the brakes to remain applied after the brake pedal is released. Continued
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  • 61. end