AUTO 1100 - Automotive Brake Systems

Credit Hours: 3.00

Objectives:

1. Diagnose and rebuild disc calipers and wheel cylinders.
2. Diagnose and rebuild master cylinders.
3. Bleed system.
4. Test and service hydraulic valves.
5. Diagnose brake pedal conditions.
6. Bleed hydraulic system.

Outcome 2: Upon completion of this course, students will be able to service drum brakes.

Objectives:

1. Machine drums.
2. Measure and diagnose drums.
3. Remove and replace brake shoes.
4. Diagnose and service self-adjusters.

Outcome 3: Upon completion of this course, students will be able to service disc brakes.

Objectives:

1. Machine rotors.
2. Measure and diagnose rotors.
3. Remove and replace brake pads.

Outcome 4: Upon completion of this course, students will be able to service parking brake.

Objectives:

1. Replace cables.
2. Adjust parking brake.

Outcome 5: Upon completion of this course, students will be able to service power assist units.

Objectives:

1. Diagnose malfunctions.
2. Remove and replace boosters.
3. Measure vacuum.

1. Introduction
   1. Class rules
   2. Grading policy
   3. Absent/tardy policy
   4. V.I.N
   5. Road testing
   6. Buying brake parts
   7. Lubricants
   8. State Law
2. Hydraulics
   1. Principles
   2. Brake fluids
      1. Types
      2. Cautions
      3. Applications
   3. Brake line service
      1. Cutting
      2. Bending
      3. S.A.E flare
      4. I.S.O flare
   4. Brake hoses
   5. Dual hydraulic circuits
   6. Flushing hydraulic system
   7. Bleeder screw service
   8. Special tool use
3. Master Cylinders
   1. Removing and replacing
   2. Diagnosing leakage
   3. Rebuilding
      1. Cleaning
      2. Honing
      3. Lubrication
   4. Bench bleeding
   5. Quick take-up design
   6. Static (residual) pressure
   7. Fluid level switch
   8. Diagnosing pedal problems
4. Drum brakes
   1. Wheel cylinders
      1. Identification
      2. Removing and replacing
      3. Rebuilding
         1. Solvents
         2. Lubrication
         3. Honing
   2. Drums
      1. Metric (mm) conversion to S.A.E.
      2. Locating and interpreting specifications
      3. Measuring and diagnosing
   3. Servo and non-servo
      1. Disassembly and assembly
      2. Lubrication
      3. Special tool use
   4. Linings
      1. Replacing and adjusting
      2. Inspection
      3. Specifications
   5. Backing plate
      1. Inspection
      2. Lubrication
      3. Cleaning
      4. Replacing
   6. Rear axle seals
      1. Inspection
      2. Removing and replacing
   7. Self-adjusters
      1. Identification
      2. Service
      3. Adjusting
      4. Operation
5. Failure warning switch
   1. Vehicle application
   2. Electrical circuitry
   3. Removing and replacing
      1. Testing warning light bulb
      2. Jumper wire
      3. Test light
      4. Voltmeter
      5. Ohmmeter
6. Disc brakes
   1. Fixed calipers and floating calipers
      1. Removing and replacing
      2. Rebuilding
      3. Lubrication
   2. Rotor Service
      1. Removing and replacing
      2. Testing minimum thick
      3. Testing TIR
      4. Testing parallelism
      5. Locating specifications
   3. Rear disc service
   4. Pads
      1. Replacing
      2. Inspection
      3. Wear sensor
      4. Specification
   5. Diagnosing malfunctions
7. Combination value
   1. Metering valve
   2. Manual offset valve
   3. Diagnosing malfunction
   4. Proportioning valve
   5. Removing and replacing
8. Machining
   1. Using a micrometer
   2. Using a drum micrometer
   3. Locating specifications
   4. Mounting rotor/drum to lathe
      1. With hub
      2. Without hub
      3. Composite
   5. Composite rotor service
   6. Lathe operation
   7. Machining drum/rotor
   8. Uni-directional rotor finish
   9. Machining rotor on car
9. Bleeding
   1. Gravity bleeding
   2. Vacuum bleeding
   3. Pressure bleeding
   4. Manual bleeding
   5. Manual metering valve offset
10. Power booster
    1. Vacuum circuit
    2. Check valve service
    3. Removing and replacing booster
    4. Diagnosing
    5. Booster operation
    6. Push rod adjustment
11. Parking brake
    1. Parking brake switch
    2. Mechanical circuitry
    3. Cable adjustment procedure
    4. Locating specification
    5. Removing and replacing cables
12. Brake lights
    1. Inspecting
    2. Diagnosing and testing
    3. Center high mounted light
13. Miscellaneous
    1. Buying brake parts
    2. State law
    3. Road testing
    4. Safety
    5. Lubricants
    6. Solvents
    7. Special brake tools
    8. Raising and supporting vehicle
    9. Flat rate