COMPETENCY BASED LEARNING

MATERIAL

Sector:
AUTOMOTIVE
Qualification:
Automotive Servicing NC II
Unit of Competency:
Service Brake System
Module Title:
SERVICING BRAKES
Technical Education and Skills Development
Authority
East Service Road, South Superhighway, Taguig, Metro Manila
 NATIONAL CERTIFICATE LEVEL 2
QUALIFICATION LEVEL

COMPETENCY-BASED LEARNING
MATERIALS

No. Unit of Competency Module Title Code

1. Service Starting System  Servicing Starting System ALT723307
2. Service Charging System  Servicing Charging System ALT723308
3. Service Engine Mechanical  Servicing Cooling System ALT723309a
System  Servicing Lubricating System ALT723309b
 Servicing Gasoline Fuel ALT723309c
System
 Servicing Air Induction ALT723309d
System
 Servicing Diesel Fuel Injector ALT723309e
4. Service Clutch System  Servicing Clutch System ALT723310
5. Service Differential and  Servicing Differential and ALT723311
Front Axle Front Axle
6. Service Manual Steering  Servicing Manual ALT723312
System Steering System
7. Overhaul Manual Transmission  Pulling-out, Disassembling ALT723313a
and Checking Manual
Transmission
 Assembling and ALT723313b
Testing Manual
Transmission
8. Service Brake System  Identifying and Explaining ALT723314a
Hydraulic Brake System
Operations and Functions
 Servicing Brakes ALT723314b
 Overhauling Brake Systems ALT723314c
9. Service Suspension System  Servicing Suspension System ALT723315
About this Competency Based Learning Material
Welcome to the module “Servicing Brakes”. This learning material contains
training materials and activities for you to complete.

The unit of competency "Service Brake System" contains the knowledge,

skills and attitudes required for Automotive Servicing. It is one of the specialized
modules at National Certificate level II (NC II).

You are required to go through a series of learning activities in order to

complete each learning outcomes of the module. In each learning outcome there
are Information Sheets and Resource Sheets (Reference Materials for further
reading to help you better understand the required activities. Follow these
activities on your own and answer the self- check at the end of each learning
outcome. You may remove a blank answer sheet at the end of each module (or
get one from your facilitator/trainer) to write your answers for each self-check. If
you have questions, don’t hesitate to ask your facilitator for assistance.

Recognition of Prior Learning (RPL)

You may already have some or most of the knowledge and skills covered in
this learning material because you have:
 been working for some time
 already completed training in this area.

If you can demonstrate to your trainer that you are competent in a

particular outcome, you don't have to do the same training again.

Talk to your trainer about having them formally recognized. If you have a
qualification or Certificate of Competence from previous training, show it to your
trainer. If the skills you acquired are still current and relevant to the unit/s of
competency they may become part of the evidence you can present for RPL. If
you are not sure about the currency of your skills, discuss this with your trainer.

After completing this module ask your trainer to assess your competency.
Result of your assessment will be recorded in your progress chart. All the
learning activities are designed for you to complete at your own pace.

Inside this learning material you will find the activities for you to complete
and at the back are the relevant information sheets for each learning outcome.
Each learning outcome may have more than one learning activities.

At the back of this learning material is a Learner Diary. Use this diary to
record important dates, jobs undertaken and other workplace events that will
assist you in providing further details to your trainer or an assessor. A Record of
Achievement is also provided for your trainer to complete once you complete the
module/training.
QUALIFICATION : AUTOMOTIVE SERVICING NC II

UNIT OF COMPETENCY : Service Brake System

MODULE : Servicing Brakes

INTRODUCTION :

The modern automotive brake system has been refined for over 100 years and has
become extremely dependable and efficient.

A brake is a device for slowing or stopping motion, as of a vehicle, especially by

contact friction.

The typical brake system consists of disk brakes in front and either disk or drum
brakes in the rear connected by a system of tubes and hoses that link the brake at
each wheel to the master cylinder. Other systems that are connected with the brake
system include the parking brakes, power brake booster and the anti-lock system.

This module will guide you in learning the basics of brake systems and provide
useful tips in performing brake system preventive maintenance. As you progress in
this module you will learn how to diagnose brake system failure and perform tests
on anti-lock brake system components.

LEARNING OUTCOMES:

At the end of this module you will be able to:

LO 1. Perform brake system preventive

maintenance. LO 2. Diagnose brake system
failure.
LO 3. Perform ABS component testing.

ASSESSMENT CRITERIA:

1. Brake clearance is adjusted to specification (drum).

2. Hydraulic brake fluid changed without spillage and filled at specified level.
3. Bleeding the hydraulic system is performed according to the required
steps and procedure.
4. Adjusting brake pedal pre-play is conducted as per specification.
5. Emergency brake is adjusted as per specification, steps and procedure.
6. Personal safety procedure is observed through-out the job.
7. Brake system linkages checked as per steps and procedure.
8. Brake lines is properly checked and without leaks and bent.
9. Checking slave and master cylinder is performed according to steps and
procedures.
10.Power booster condition is checked according to the required steps and
procedures.
11.Checking wheel cylinder/caliper is performed accurately.
12.Personal safety procedure is observed throughout the activity.
13.ABS voltage is checked as per specification.
14.Fluid pressure checked as specified.
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 15.Amperage draw is checked according to the required manufacturer’s
specification.
16.Testing and checking wiring circuit are performed accurately.
17.Used appropriate tools and equipment.
18.Apply personal, vehicle and workshop safety procedure.

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QUALIFICATION : Automotive Servicing NC II

UNIT OF COMPETENCY : Service Brake System

MODULE TITLE : Servicing Brakes

LEARNING OUTCOME #1 : Perform brake system preventive maintenance

ASSESSMENT CRITERIA:

1. Brake clearance is adjusted to specification (drum).

2. Hydraulic brake fluid changed without spillage and filled at specified level.
3. Bleeding the hydraulic system is performed according to the required
steps and procedure.
4. Adjusting brake pedal pre-play is conducted as per specification.
5. Emergency brake is adjusted as per specification, steps and procedure.
6. Personal safety procedure is observed through-out the job

RESOURCES:

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LEARNING EXPERIENCES / ACTIVITIES
LO# 1 – Perform brake system preventive maintenance
LEARNING ACTIVITIES SPECIAL INSTRUCTIONS

- Adjust brake clearance to specification - Automotive Encyclopedia

- Technique in changing and filling - Preventive Handbook

fluid to master cylinder
- Bosch Handbook
- Steps and procedure in bleeding
hydraulic brakes. - Today’s Technician

- Adjust pedal free-play - ILO Learning Element Maintenance

- Adjust emergency brakes linkage - Specification Manual

- Fabricate and replace brake lines.

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 INFORMATION SHEET NO. LO#1-1

Adjusting Brake Clearance to Specification

1. Remove Rear wheels

a. Using a tire wrench, loosen the wheel nut

¼ to ‘h turn before raising the vehicle.

b. Raise vehicle and remove rear wheel.

c. Remove rear brake drum. If the

drum cannot be remove easily insert
a screw driver through the hole in
the braking plate and loosen adjust
wheel.

Note: Never step on the brake pedal while

a drum is off or the wheel cylinder will
pop apart.

2. Inspect Brake
Lining For weak
Measure brake lining thickness then refer
to specification.

Measure at the thinnest area

Note: If any of the brake shoe have to be

replace, all of the brake shoe of the
wheel must be replace for even
braking.

Note: Brake shoe dust contain asbestos

and Is cancerous
3. Inspection of Brake drum

a. Measure drum inner diameter and

refer to specification.
b. Check drum for scoring.

Note: Lathe or Replace drum if necessary

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4. Clean Brake Drum and Shoes

Clean the brake shoe and lining with

sand paper to remove stain oil clean also
the brake drum and baking plate.

5. Check wheel cylinder for

leak Note: Overhaul If

found leak

6. Check also for faulty retracting spring,

loose carrier or ancestor plate, self
adjuster not operating.

7. Assemble drum to backing plate and

tires and locate adjusting hole at back
of backing plate or at the drum.

8. Adjust the Shoe clearance

a. Using the brake adjusting tool, turn

the adjuster until the wheel can no
longer be rotated.

b. Turn the adjuster slowly, notch by

notch until the wheel can be
rotated.

Note: Depress the pedal occasionally.

c. Repeat step (b) until the wheels

rotate slowly with a slight drag.

9. Drive test new adjusted brake. Rear

brake must react together.

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Check fluid level and refilling

1. Check fluid level

If Reservoir is plastic the level

should be between max and min or
6mm for top or reservoir.

2. Add Fluid if necessary.

Important:
Do not let the reservoir run empty.
Check the level frequently.

Note: Do not allow fluid to scatter at

any car parts especially on painted
parts. Brake fluid will destroy your
car parts.

Bleeding Hydraulic Brake (Manual)

1. Raise the vehicle wheel.

The wheel cylinder that is farthest from
the master cylinder (Rear Right Wheel)

2. Remove bleeder plug cap from the

bleeder screw or plug

3. Connect a Transparent hose to the

bleeder plug and insert the other end
in a half full container of fresh fluid.

Note: one end of the tube must be

submerge in the fluid to prevent air
from entering the system.

4. Pump the brake.

Pedal several limes
(this Is done by the assistant)

5. While tile pedal is depressed, loosen

the bleeder plug about ½- turn to
allow fluid to flow.

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6. Keep on pumping the pedal until
bubbles are drained

7. Add new fluid to

reservoir Important:
Do not let the reservoir run empty.
Check the level frequently

Adjusting Pedal free Travel (with booster)

1. Disconnect wiring connector 1 for the

stop light switch.

2. Loosen lock nut 3 of stop light switch

and unscrew a few turn.

3. Loosen lock nut 4 of push rod

4. Adjust pedal height by turning the push rod

5. Screw in stop lamp switch until its pedal

slopped lightly contact with the cushion
tighten locknut.

6. Be sure that the pedal stopper of the

switch is not touching the cushion
hardly, or the pedal height may be
reduced.

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7. Slightly push the brake pedal with your
finger until it meets resistance

8. Measure pedal stroke refer to specification

10. Tighten lock nut and measure

again until pedal free play is correct

11. Start engine and confirm if free play is correct.

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Emergency Brake/Parking Brake

1. Set parking brake to a fully applied position

2. Raise the car and make sure its wheels

would not rotate. If the wheels rotate,
proper adjustments must be made.

3. Release the parking brake, tighten

adjustment lock nut and adjust the nut
until tire cannot be rotated.

4. Stop tightening when you can no longer

turn the wheels by hand.

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5. Loosen the adjusting nut slightly until
wheels turns with only a slight drag.

6. Check cables for fraying, breakage

and deterioration

7. Spray all exposed metals with

penetrating oils.

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8. Clean off threaded areas and make
sure the tightening nuts are not
damage

9. Lower the vehicles and release

parking brakes.

Fabricating and Replacing Brake Lines

Inspecting Brake Line Tubing

Check for bend, leakage, rupture and kinks.

Note: When replacing a brake line a always

used steel piping to withstand high
pressure and corrosion

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1. Use recommended steel tube size and
tube nuts.

2. To determine correct length of lube,

measure remove tube and add 4mm
for each flare.

3. Use tube cutter to cut to required length

4. Clean any burrs after cutting

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5. Place tube nut in correct direction.

6. Place tube in flaring bar with the end

protruding slightly above the face of
the bar.

7. Firmly clamp the tube in the bar so

the force exerted during flaring does
not push the tubing down through the
bar.

8. To fold over the end of the tubing

place adaptor or anvil in place
over the tube opening.

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9. Tighten down the flaring clamp.

10. Loosen flaring clamp and check to

see that the end of the tubing is
properly belled.

11. Install the cone onto the tube

opening and retighten flaring clamp.

12. The cone completes the double flare

by folding the tubing back on itself.
This doubles its thickness and create
two sealing surfaces.

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13. Bend the replacement tube to
match the original tube using
tubing bender.

14. Clean brake tubing by flushing it

with clean broke fluid.

15. Install the replace brake tube,

maintaining adequate clearance to
metal edges and moving or vibrating
parts.

16. Install brake tube and tighten tube

nuts to specification.

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17. Bleed the hydraulic system

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QUALIFICATION : Automotive Servicing NC II

UNIT OF COMPETENCY : Service Brake System

MODULE TITLE : Servicing Brakes

LEARNING OUTCOME #2 : Diagnose brake system failure

ASSESSMENT CRITERIA:

1. Brake system linkages checked as per steps and procedure.

2. Brake lines is properly checked and without leaks and bent.
3. Checking slave and master cylinder is performed according to steps and
procedures.
4. Power booster condition is checked according to the required steps and
procedures.
5. Checking wheel cylinder/caliper is performed accurately.
6. Personal safety procedure is observed throughout the activity.

RESOURCES:

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LEARNING EXPERIENCES / ACTIVITIES
LO# 2 – Diagnose brake system failure
LEARNING ACTIVITIES SPECIAL INSTRUCTIONS

- Troubleshoot Brake System - Automotive Encyclopedia

- Preventive Handbook
Maintenance

- Bosch Handbook

- Today’s Technician

- ILO Learning Element

- Specification Manual

Code No. Date: Date: Page #

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 INFORMATION SHEET NO. LO#2–1

TROUBLESHOOTING BRAKES

Excessive Pedal Travel Brakes Drag

1. Air in brake lines. 1. Contaminated brake fluid.
2. Fluid leak. 2. Maladjusted parking brake cables.
3. Faulty automatic adjusters. 3. Faulty automatic adjusters.
4. Maladjusted master cylinder push rod. 4. Sticking wheel cylinders or
5. Worn drum brake lining. caliper pistons.
6. Fluid bypassing quick take-up valve to 5. Brake pedal binding at pivot.
reservoir. 6. Maladjusted master cylinder push rod.
7. Partial brake system failure. 7. Malfunctioning master cylinder.
8. Faulty metering valve.
Excessive Pedal Effort 9. Faulty proportioning valve.
1. Glazed or poor quality brake lining. 10.Restricted lines or hoses.
2. Sticking wheel cylinder or caliper pistons.
3. Calipers binding on mounting pins. Brakes Chatter
4. Binding or damaged pedal linkage. 1. Loose or missing brake
5. Partial brake system failure. assembly attaching parts.
6. Excessively worn brake linings. 2. Bent or distorted brake shoes.
7. Clogged quick take-up valve. 3. Glazed brake lining.
8. Insufficient vacuum to power brake unit. 4. Loose caliper attaching bolts.
9. Restricted or clogged lines or hoses. 5. Loose front suspension parts.
10.Contaminated brake fluid. 6. Heat-spotted or scored brake
11.Malfunctioning master cylinder. drum or rotor.
12.Faulty proportioning valve. 7. Excessive lateral runout of rotor.
13.Leaking or loose power brake unit vacuum 8. Out-of-parallel rotor.
hose. 9. Loose wheel bearings.
14.Defective power brake unit.
Brakes Pull to One Side
Pedal Spongy 1. Unequal air pressure in front tires.
1. Air in hydraulic system. 2. Unmatched tires on same axle.
2. Bent or distorted drum brake shoes. 3. Grease or fluid on brake lining.
4. Loose caliper attaching bolts.
Pedal Pulsates 5. Seized wheel cylinder or caliper.
1. Out-of-round drums. 6. Restricted brake lines or hoses.
2. Successive lateral runout of rotor. 7. Worn or damaged wheel bearings.
8. Loose front suspension parts.
Slow Pedal Return 9. Faulty combination valve.
1. Clogged holes in quick take-up valve.
Scraping Noise from Brakes
Brake Grab 1. Worn Out brake lining.
1. Grease or fluid on linings. 2. Uneven brake lining wear.
2. Make adjusted parking brake cables. 3. Contaminated brake lining.
3. Heat-spotted or scored brake drums or 4. Bent, broken, distorted brake shoes.
rotors 5. Loose or missing brake
4. Maladjusted master cylinder push rod. assembly attaching parts.
5. Loose caliper attaching bolts. 6. Incorrect wheel bearing adjustment.
6. Binding brake pedal mechanism. 7. Loose front suspension parts.
7. Malfunctioning power brake unit. 8. Interference between caliper and
wheel or rotor.
Brakes Fade 9. Scored or tapered brake drum.
1. Defective master cylinder.
2. External fluid leak.
3. Vapor lock in system.
4. Thin brake drums.
5. Crystallized brake lining.

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Brakes Squeak

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1. Worn out brake lining.
2. Glazed or poor quality brake lining.
3. Contaminated brake lining.
4. Excessive brake lining dust.
5. Weak, damaged, or incorrect shoe retracting springs
6. Heat-spotted or scored brake drum or rotor.
7. Burred or rusted caliper.
8. Rough or dry drum brake backing plate ledges.

Brake Warning Light On

1. Insufficient fluid in master cylinder reservoirs.
2. Hydraulic system failure.
3. Parking brake ON or not fully released.
4. Insufficient vacuum to power brake unit.

GM SINGLE DIAPHRAGM UNIT

With regard to specific power brake problems

1. Hard pedal could be caused by: a restricted air filter vacuum failure; defective
diaphragm; worn-out distorted action plate or levers; cracked or power piston or
retainer.
2. Failure to release could be caused by: a block passage in power piston; air valve
stuck closed broken piston return spring or air valve spring
3. Dragging brakes could be caused by a piston (master cylinder push rod) of
incorrect length. On off-limits push rod will cause primary cup to overlap
compensating port of master cylinder.

A special disassembly and reassembly tool is required to unlock the two

housings of the typical General Motors single or tandem diaphragm power brake
unit shown.

After disassembly, components may be inspected and replaced if defective. The

power piston should not be disassembled. The inside diameter of the diaphragm
should be lubricated and fit into the diaphragm support.

A new diaphragm retainer must be installed, using a special driving tool.

The special disassembly and reassembly tool is used to lock the two housings
together. A special gauge is used to check master cylinder push “height” with the
power unit placed in a padded vise with front housing up. If the push rod is out of
limits, it must be replaced with an adjustable service push rod.

POWER BRAKE SYSTEM SERVICE

Generally, the same kinds of operational problems can occur on cars with either
power brakes or standby brakes. Excessive pedal effort, excessive pedal travel
dragging brakes, and grabbing brakes all could be caused by a malfunction in cars
with or without power brakes.

However, note in TROUBLESHOOTING BRAKES how much more prevalent in the

possible causes are in the mechanical and hydraulic parts of the overall brake
system rather than in the power brake unit. There is a time when brake trouble
occurs, these systems should be checked out first.

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QUALIFICATION : Automotive Servicing NC II

UNIT OF COMPETENCY : Service Brake System

MODULE TITLE : Servicing Brakes

LEARNING OUTCOME #3 : Perform ABS component testing

ASSESSMENT CRITERIA:

1. ABS voltage is checked as per specification.

2. Fluid pressure checked as specified.
3. Amperage draw is checked according to the required manufacturer’s
specification.
4. Testing and checking wiring circuit are performed accurately.
5. Used appropriate tools and equipment.
6. Apply personal, vehicle and workshop safety procedure.

RESOURCES:

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LEARNING EXPERIENCES / ACTIVITIES
LO# 3 – Perform ABS component testing
LEARNING ACTIVITIES SPECIAL INSTRUCTIONS

- Test ABS component - Automotive Encyclopedia

a. Hydraulic unit - Preventive Handbook

b. Electrical System - Today’s Technician

c. Wheel Speed Sensor - ILO Learning Element

Maintenance
d. ECU
- Specification Manual

Code No. Date: Date: Page #

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 INFORMATION SHEET NO. LO#3–1

ANTI-LOCK BRAKE SYSTEM

ANTI-LOCK BRAKE WARNING LIGHT

The ABS warning light is located in the instrument panel warning light cluster. If it
illuminates while driving, it indicates that there is a problem in the ABS.

• A past failure is indicated one time, each time the engine is started. The flash
pattern is the same as the warning light indication mode.

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DIAGNOSIS

SELF TEST CODES

Code No. Date: Date: Page #

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PERFORMANCE TEST

Learner’s Name Date:

Test Attempt
st
Competency: Service Brake System 1 2nd 3rd

Directions: OVERALL EVALUATION

Level
CALL INSTRUCTOR, ask Achieved PERFORMANCE LEVELS
instructor to assess 4 – Can perform this skill without supervision and with
your performance in the initiative and adaptability to problem situations.
following critical task 3 – Can perform this skill satisfactorily without
and performance criteria assistance or supervision.
below. 2 – Can perform this skill satisfactorily but requires
some assistance and/or supervision.
You will be rate based 1 – Can perform parts of this skill satisfactorily, but
on the overall evaluation requires considerable assistance and/or supervision.
on the right side.
Instructor will initial level achieved.

PERFORMANCE STANDARDS
For acceptable achievement, all items should receive a “Yes” Yes No N/A
or “N/A” response.
1. adjust brake clearance, according to specification

2. change and fill fluid to master cylinder

3. bleed hydraulic brakes

4. troubleshoot, fabricate and replace brake lines

5. adjust emergency brakes linkage

6. test the following ABS component
a. hydraulic unit
b. electrical system
c. wheel speed sensor
d. ECU
7. adjust pedal free-play according to specification

8. proper use of tools and materials

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Learner’s diary
DIARY NOTES
Record important dates, jobs undertaken and other workplace events that will assist you in providing
further details to an Assessor.
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Record of Achievement

Servicing Brake System

Learning Outcome #1 - Perform brake system preventive maintenance

Performance Criteria:
1. Function of brakes explained
2. Component of hydraulic brake identified.
3. Principle of operation of hydraulic brake explained.
4. Types of brakes explained and classified.

COMMENTS:
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Learner has satisfied the above performance

criteria. Learner’s signature:

………………………………………. Trainer’s signature:

……………………………………….. Date:

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Record of Achievement

Servicing Brake System

Learning Outcome #2 - Diagnose brake system failure

Performance Criteria:

1. Brake system linkages checked as per steps and procedure.

2. Brake lines is properly checked and without leaks and bent.
3. Checking slave and master cylinder is performed according to
steps and procedures.
4. Power booster condition is checked according to the required
steps and procedures.
5. Checking wheel cylinder/caliper is performed accurately.
6. Personal safety procedure is observed throughout the activity.

COMMENTS:
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Learner has satisfied the above performance

criteria. Learner’s signature:

………………………………………. Trainer’s signature:

……………………………………….. Date:

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Record of Achievement

Servicing Brake System

Learning Outcome #3 - Perform ABS component testing

Performance Criteria:

1. ABS voltage is checked as per specification.

2. Fluid pressure checked as specified.
3. Amperage draw is checked according to the required
manufacturer’s specification.
4. Testing and checking wiring circuit are performed accurately.
5. Used appropriate tools and equipment.
6. Apply personal, vehicle and workshop safety procedure.

COMMENTS:
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Learner has satisfied the above performance

criteria. Learner’s signature:

………………………………………. Trainer’s signature:

……………………………………….. Date:

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Code No. Date: Date: Page #

Servicing Brakes Developed Revised
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Nov. 28, 2003 March 1, 31
ACKNOWLEDGEMENT

Copyright TESDA
Centex: RTC VI = Talisay

First Published OCTOBER 2003

This draft was prepared at the Competency-Based Learning Materials

Development Workshop conducted at the Cagayan de Oro (Bugo) School of Arts
& Trades, from 23rd to 27th October 2003.

It was based on the competency standard for Automotive Service Technician

developed by the Skill Standard and Certification Office (SSCO), and the
Competency-Based Curriculum Instructional Modules developed by the National
Institute for Technical Vocational Education and Training (NITVET), Technical
Education and Skills Development Authority (TESDA).

Some materials for contextual learning (science, math and communication) were
supplied by Academic Teachers.

This learning instrument was developed by the following

personnel: Technology Instructors :

Academic Teachers :

Vocational Institution Supervisor:

Facilitator :

This work was produced with funding provided by TESDA.

Code No. Date: Date: Page #

Servicing Brakes Developed Revised
ALT723314
Nov. 28, 2003 March 1, 32