2013 NATEF Task Area A-5 Brake Systems 7-2013

1. 2013 NATEF Task Area A-5 Brake Systems7-2013 • A. General Brake System Diagnosis • B. Hydraulic System Diagnosis & Repair • C. Drum Brake Diagnosis & Repair • D. Disc Brake Diagnosis & Repair • E. Power Assist Diagnosis & Repair • F. Wheel Bearing, Parking Brake, Electrical D & R • G. Anti-lock Brake & Traction Control Systems

2. NATEF Task Area A-5 Brake Systems Identify and interpret brake system concerns; determine necessary action. A5.A.1 P-1

3. NATEF Task Area A-5 Brake Systems Research applicable vehicle and service information, such as brake system operation, vehicle service history, service precautions, and technical service bulletins. A5.A.2 P-1

4. NATEF Task Area A-5 Brake Systems Describe procedure for performing a road test to check brake system operation; including an anti-lock brake system (ABS). Consider doing it in a parking lot! A5.A.3 P-1 The feel and sound of ABS.When ABS is activated, you may experience a slight vibration or a rapid pulsation of the brake pedal almost as if the brakes are pushing back at you. At times, you will feel the pedal suddenly drop. The valves in the ABS unit may make a grinding, scraping or buzzing noise. This means your ABS is working. Continue to apply firm pressure and steer. Do not take your foot off the brake pedal. A brake inspection should consist of: 1. A road test to check brake operation2. A wheels-off inspection to measure brake rotor thickness. Every brake rotor has a spec for thickness to ensure safe operation. When they are outside this measurement, they cannot be used.3. Measuring the thickness of the brake material to determine if it is above a minimum thickness. The brake pads not only provide the necessary friction, but also help dissipate heat. If pads are too thin, they cannot perform these two important functions.4. Inspecting the brake calipers for damage such as torn dust boots, sticking pistons, etc. If the brake calipers are not performing as designed, they will not allow enough force to be applied to the brake pads to stop the vehicle.

5. NATEF Task Area A-5 Brake Systems Install wheel and torque lug nuts. A5.A.4 P-1

6. NATEF Task Area A-5 Brake Systems “Oldie” Complete work order to include customer information, vehicle identifying information, verify customer concern, related service history, cause, correction. Have the Customer Sign & Date the R.O.

7. NATEF Task Area A-5 Brake Systems “Oldie” Locate and interpret vehicle and major component identification numbers (VIN, vehicle certification labels, calibration decals).

8. NATEF Task Area A-5 Brake Systems Diagnose pressure concerns in the brake system using hydraulic principles (Pascal’s Law). A5.B.1 P-1

9. NATEF Task Area A-5 Brake Systems Measure brake pedal height, travel, and free play (as applicable); determine necessary action. A5.B.2 P-1

10. NATEF Task Area A-5 Brake Systems Check master cylinder for internal/external leaks and proper operation; determine necessary action. A5.B.3 P-1

11. NATEF Task Area A-5 Brake Systems Remove, bench bleed, and reinstall master cylinder. A5.B.4 P-1

12. NATEF Task Area A-5 Brake Systems Diagnose poor stopping, pulling or dragging concerns caused by malfunctions in the hydraulic system; determine necessary action. A5.B.5 P-3

13. NATEF Task Area A-5 Brake Systems Inspect brake lines, flexible hoses, and fittings for leaks, dents, kinks, rust, cracks, bulging, and wear; check for loose fittings & supports; determine necessary action. A5.B.6 P-1

14. NATEF Task Area A-5 Brake Systems Replace brake lines, hoses, fittings, and supports. A5.B.7 P-2

15. NATEF Task Area A-5 Brake Systems Fabricate brake lines using proper material and flaring procedures (double flare and ISO types). A5.B.8 P-2

16. NATEF Task Area A-5 Brake Systems Select, handle, store, and fill brake fluids to proper level. A5.B.9 P-1

17. NATEF Task Area A-5 Brake Systems Inspect, test, and/or replace components of brake warning light system. A5.B.10 P-3

18. NATEF Task Area A-5 Brake Systems Identify components of brake warning light system. A5.B.11 P-3

19. NATEF Task Area A-5 Brake Systems “Oldie” Inspect, test, replace metering (hold-off), proportioning (balance), pressure differential, & combination valves.

20. NATEF Task Area A-5 Brake Systems “Oldie” Inspect, test, replace, and adjust height (load) sensing proportioning valve.

21. NATEF Task Area A-5 Brake Systems “Oldie” Inspect, test, replace, and adjust height (load) sensing proportioning valve.

22. NATEF Task Area A-5 Brake Systems Bleed and/or flush brake system. A5.B.12 P-1

23. NATEF Task Area A-5 Brake Systems “Oldie” Flush hydraulic system.

24. NATEF Task Area A-5 Brake Systems Test brake fluid for contamination. A5.B.13 P-1 Green: Battery OK, i.e.: No water contained in the brake fluid. Yellow: Less than 1% of water content in brake fluid. Yellow/ Yellow: Approx. 2% of water content in brake fluid. Yellow/ Yellow/ Red: Approx. 3% water content in brake fluid. The brake fluid should be changed. Yellow/ Yellow/ Red/ Red: At least 4% of water content in brake fluid. The brake fluid must be changed urgently.

25. NATEF Task Area A-5 Brake Systems Diagnose poor stopping, noise, vibration, pulling, grabbing, dragging or pedal pulsation concerns; determine necessary action. A5.C.1 P-1

26. NATEF Task Area A-5 Brake Systems Remove, clean, inspect, and measure brake drum diameter; determine necessary action. A5.C.2 P-1

27. NATEF Task Area A-5 Brake Systems Refinish brake drum & measure final drum diameter; compare with specifications. A5.C.3 P-1

28. NATEF Task Area A-5 Brake Systems Remove, clean, and inspect brake shoes, springs, pins, clips, levers, adjusters/self-adjusters, other related brake hardware, and backing support plates; lubricate and reassemble. A5.C.4 P-1

29. NATEF Task Area A-5 Brake Systems Inspect wheel cylinders for leaks & proper operation; remove & replace as needed. A5.C.5 P-2

30. NATEF Task Area A-5 Brake Systems Pre-adjust brake shoes and parking brake; install brake drums or drum/hub assemblies and wheel bearings; perform final checks and adjustments. A5.C.6 P-2

31. NATEF Task Area A-5 Brake Systems Diagnose poor stopping, noise, vibration, pulling, grabbing, dragging, or pulsation concerns; determine necessary action. A5.D.1 P-1

32. NATEF Task Area A-5 Brake Systems Remove and clean caliper assembly; inspect for leaks and damage/wear to caliper housing; determine necessary action. A5.D.2 P-1

33. NATEF Task Area A-5 Brake Systems Clean and inspect caliper mounting and slides/pins for proper operation, wear, and damage; determine necessary action. A5.D.3 P-1

34. NATEF Task Area A-5 Brake Systems Remove, inspect, and replace pads and retaining hardware; determine necessary action. A5.D.4 P-1

35. NATEF Task Area A-5 Brake Systems “Oldie” Disassemble and clean caliper assembly; inspect parts for wear, rust, scoring, and damage; replace seal, boot, and damaged or worn parts.

36. NATEF Task Area A-5 Brake Systems Lubricate and reinstall caliper, pads, and related hardware; seat pads and inspect for leaks. A5.D.5 P-1

37. NATEF Task Area A-5 Brake Systems Clean and inspect rotor; measure rotor thickness, thickness variation, and lateral runout; determine necessary action. A5.D.6 P-1

38. NATEF Task Area A-5 Brake Systems Remove and reinstall rotor. A5.D.7 P-1

39. NATEF Task Area A-5 Brake Systems Refinish rotor on vehicle; measure final rotor thickness and compare with specifications. A5.D.8 P-1

40. NATEF Task Area A-5 Brake Systems Refinish rotor off vehicle; measure final rotor thickness and compare with specifications. A5.D.9 P-1

41. NATEF Task Area A-5 Brake Systems Retract and re-adjust caliper piston on an integrated parking brake system. A5.D.10 P-3

42. NATEF Task Area A-5 Brake Systems Check brake pad wear indicator; determine necessary action. A5.D.11 P-2

43. NATEF Task Area A-5 Brake Systems Describe importance of operating vehicle to burnish/break-in replacement brake pads according to manufacturer’s recommendations. A5.D.12 P-1 30/30/30 Burnish Procedure • Perform 30 stops from 30 miles per hour with a 30-second cooling interval between stops. These stops will be performed at a decelerating rate of 12 feet per second or less. This means that it should be a gentle easy stop. • The 30/30/30 Burnish Procedure beds the pads and shoes into the rotor and drums. It also deposits the necessary friction transfer to the rotors and drums for optimum brake performance. • Following this procedure also assures that your customer will have excellent brake performance from the first time he or she drives the car after brake service has been performed. You should not depend on your customer to break in the brake job. The only way to assure that it is done correctly is to incorporate it into your brake job test drive.

44. NATEF Task Area A-5 Brake Systems Check brake pedal travel with, and without, engine running to verify proper power booster operation. A5.E.1 P-2

45. NATEF Task Area A-5 Brake Systems Check vacuum supply (manifold or auxiliary pump) to vacuum-type power booster. A5.E.2 P-1

46. NATEF Task Area A-5 Brake Systems Inspect vacuum-type power booster unit for leaks; inspect the check-valve for proper operation; determine necessary action. A5.E.3 P-1

47. NATEF Task Area A-5 Brake Systems Inspect and test hydraulically-assisted power brake system for leaks and proper operation; determine necessary action. A5.E.4 P-3

48. NATEF Task Area A-5 Brake Systems Measure and adjust master cylinder pushrod length. A5.E.5 P-3

49. NATEF Task Area A-5 Brake Systems Diagnose wheel bearing noises, wheel shimmy, and vibration concerns; determine necessary action. A5.F.1 P-3

50. NATEF Task Area A-5 Brake Systems Remove, clean, inspect, repack, and install wheel bearings; replace seals; install hub and adjust bearings. A5.F.2 P-1