Competency Based Learning Material: Servicing Brakes

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
7. Service Starting System
8. Service Charging System
9. Service Engine Mechanical
System
10.
Service Clutch System
11.
Service Differential and Front Axle
12.
13.
Service Steering System

Overhaul Manual Transmission
14. Service Brake System
15.
Service Suspension System
Module Title
Repairing Starting System
Repairing Charging System
Servicing Cooling System
Servicing Lubricating System
Servicing Gasoline Fuel System
Servicing Air Induction System
Servicing Diesel Fuel Injector
Servicing and Repairing Clutch
System
Servicing Differential and Front
Axle
Servicing Steering System
Pulling-out, Disassembling and
Checking Manual Transmission
Assembling and Testing Manual
Transmission
Identifying and Explaining
Hydraulic Brake System
Operations and Functions
Code
ALT723307
ALT723308
ALT723309a
ALT723309b
ALT723309c
ALT723309d
ALT723309d
ALT723310
Servicing Brakes
ALT723314b
Overhauling Brake Systems

Servicing Suspension System
Identifying and Explaining
Suspension System Operating
Principles, Components and
Functions
(Conventional and Air
Suspension)
Servicing and Repairing
Suspension System
ALT723314c
ALT723315a
ALT723311
ALT723312
ALT723313a
ALT723313b
ALT723314a
ALT723315b
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 selfcheck 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, dont 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.
15. Amperage draw is checked according to the required manufacturers specification.
16. Testing and checking wiring circuit are performed accurately.
17. Used appropriate tools and equipment.
18. Apply personal, vehicle and workshop safety procedure.
Code No.
ALT723314
Servicing Brakes
Date: Developed Date: Revised

Nov. 28, 2003
March 1, 2006
Page #
QUALIFICATION
Automotive Servicing NC II
UNIT OF COMPETENCY :
Service Brake System
MODULE TITLE
Servicing Brakes
LEARNING OUTCOME #1 :
Perform brake system preventive maintenance
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.
RESOURCES:
Code No.
ALT723314
Servicing Brakes

Nov. 28, 2003
March 1, 2006
Page #
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 fluid to

master cylinder
Preventive Handbook
Bosch Handbook
Steps and procedure in bleeding hydraulic

brakes.
Todays Technician
Adjust pedal free-play
ILO Learning Element Maintenance
Adjust emergency brakes linkage
Specification Manual
Fabricate and replace brake lines.
Code No.
ALT723314
Servicing Brakes

Nov. 28, 2003
March 1, 2006
Page #
INFORMATION SHEET NO. LO#1-1

Adjusting Brake Clearance to Specification
1. Remove Rear wheels
a. Using a tire wrench, loosen the
wheel nut 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
Measuring 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
necessary
Code No.
ALT723314
Replace
drum
if
Servicing Brakes

Nov. 28, 2003
March 1, 2006
Page #
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 ancetor 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.
Code No.
ALT723314
Servicing Brakes

Nov. 28, 2003
March 1, 2006
Page #
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 - turn to allow
fluid to flow.
Code No.
ALT723314
Servicing Brakes

Nov. 28, 2003
March 1, 2006
Page #
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.
Code No.
ALT723314
Servicing Brakes

Nov. 28, 2003
March 1, 2006
Page #
7. Slightly push the brake pedal with your

finger until it meets resistance
8. Measure pedal
specification
stroke
refer
to
10. Tighten lock nut and measure again

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

correct.
Emergency Brake/Parking Brake
Code No.
ALT723314
Servicing Brakes

Nov. 28, 2003
March 1, 2006
Page #
1. Set parking brake to a fully applied

position
2. Raise car and make sure its secure

wheel should not rotate due to no. I if
wheel rotate proper adjustments must
be made.
3. Released parking brake, loosen

adjustment lock nut adjust nut until tire
cannot be rotated
4. When you can no longer turn the
wheels by hand stop tightening
Code No.
ALT723314
Servicing Brakes

Nov. 28, 2003
March 1, 2006
Page #
5. Adjust adjusting nut until wheels turns

with only a slight drag.
6. Check cables for fraying, breakage

and deterioration
7. Spray all exposed metals with

penetrating oils.
Code No.
ALT723314
Servicing Brakes

Nov. 28, 2003
March 1, 2006
Page #
10
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
Code No.
ALT723314
Servicing Brakes

Nov. 28, 2003
March 1, 2006
Page #
11
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
Code No.
ALT723314
Servicing Brakes

Nov. 28, 2003
March 1, 2006
Page #
12
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.
Code No.
ALT723314
Servicing Brakes

Nov. 28, 2003
March 1, 2006
Page #
13
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.
Code No.
ALT723314
Servicing Brakes

Nov. 28, 2003
March 1, 2006
Page #
14
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.
Code No.
ALT723314
Servicing Brakes

Nov. 28, 2003
March 1, 2006
Page #
15
17. Bleed the hydraulic system
Code No.
ALT723314
Servicing Brakes

Nov. 28, 2003
March 1, 2006
Page #
16
QUALIFICATION
: Automotive Servicing NC II

MODULE TITLE
: Servicing Brakes
LEARNING OUTCOME #2 : Diagnose brake system failure

1.
2.
3.
4.
5.
6.
Brake system linkages checked as per steps and procedure.

Brake lines is properly checked and without leaks and bent.
Checking slave and master cylinder is performed according to steps and procedures.
Power booster condition is checked according to the required steps and procedures.
Checking wheel cylinder/caliper is performed accurately.
Personal safety procedure is observed throughout the activity.
RESOURCES:
Code No.
ALT723314
Servicing Brakes

Nov. 28, 2003
March 1, 2006
Page #
17

LO# 2 Diagnose brake system failure
LEARNING ACTIVITIES
-
Troubleshoot Brake System
Code No.
ALT723314
-
Preventive Handbook Maintenance
Bosch Handbook
Todays Technician
ILO Learning Element
Servicing Brakes

Nov. 28, 2003
March 1, 2006
Page #
18
INFORMATION SHEET NO. LO#21

TROUBLESHOOTING BRAKES
Excessive Pedal Travel
1. Air in brake lines.
2. Fluid leak.
3. Faulty automatic adjusters.
4. Maladjusted master cylinder push rod.
5. Worn drum brake lining.
6. Fluid bypassing quick take-up valve to
reservoir.
7. Partial brake system failure.
Excessive Pedal Effort
1. Glazed or poor quality brake lining.
2. Sticking wheel cylinder or caliper pistons.
3. Calipers binding on mounting pins.
4. Binding or damaged pedal linkage.
5. Partial brake system failure.
6. Excessively worn brake linings.
7. Clogged quick take-up valve.
8. Insufficient vacuum to power brake unit.
9. Restricted or clogged lines or hoses.
10. Contaminated brake fluid.
11. Malfunctioning master cylinder.
12. Faulty proportioning valve.
13. Leaking or loose power brake unit vacuum
hose.
14. Defective power brake unit.
Pedal Spongy
1. Air in hydraulic system.
2. Bent or distorted drum brake shoes.
Pedal Pulsates
1. Out-of-round drums.
2. Successive lateral runout of rotor.
Slow Pedal Return
1. Clogged holes in quick take-up valve.
Brake Grab
1. Grease or fluid on linings.
2. Make adjusted parking brake cables.
3. Heat-spotted or scored brake drums or rotors
5. Loose caliper attaching bolts.
6. Binding brake pedal mechanism.
7. Malfunctioning power brake unit.
Brakes Fade
1. Defective master cylinder.
2. External fluid leak.
3. Vapor lock in system.
4. Thin brake drums.
5. Crystallized brake lining.
Code No.
ALT723314
Brakes Drag
1. Contaminated brake fluid.
2. Maladjusted parking brake cables.
3. Faulty automatic adjusters.
4. Sticking wheel cylinders or caliper
pistons.
5. Brake pedal binding at pivot.
7. Malfunctioning master cylinder.
8. Faulty metering valve.
9. Faulty proportioning valve.
10. Restricted lines or hoses.
Brakes Chatter
1. Loose or missing brake assembly
attaching parts.
2. Bent or distorted brake shoes.
3. Glazed brake lining.
5. Loose front suspension parts.
6. Heat-spotted or scored brake drum or
rotor.
7. Excessive lateral runout of rotor.
8. Out-of-parallel rotor.
9. Loose wheel bearings.
Brakes Pull to One Side
1. Unequal air pressure in front tires.
2. Unmatched tires on same axle.
3. Grease or fluid on brake lining.
5. Seized wheel cylinder or caliper.
6. Restricted brake lines or hoses.
7. Worn or damaged wheel bearings.
9. Faulty combination valve.
Scraping Noise from Brakes
1. Worn Out brake lining.
2. Uneven brake lining wear.
3. Contaminated brake lining.
4. Bent, broken, distorted brake shoes.
5. Loose or missing brake assembly
attaching parts.
6. Incorrect wheel bearing adjustment.
8. Interference between caliper and wheel
or rotor.
9. Scored or tapered brake drum.
Servicing Brakes

Nov. 28, 2003
March 1, 2006
Page #
19
Brakes Squeak
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.
Code No.
ALT723314
Servicing Brakes

Nov. 28, 2003
March 1, 2006
Page #
20
QUALIFICATION
: Automotive Servicing NC II

MODULE TITLE
: Servicing Brakes
LEARNING OUTCOME #3 : Perform ABS component testing

3. Amperage draw is checked according to the required manufacturers specification.
RESOURCES:
Code No.
ALT723314
Servicing Brakes

Nov. 28, 2003
March 1, 2006
Page #
21

LO# 3 Perform ABS component testing
LEARNING ACTIVITIES
-
Test ABS component
a. Hydraulic unit
Preventive Handbook
b. Electrical System
Todays Technician
c. Wheel Speed Sensor
ILO Learning Element Maintenance
d. ECU
Code No.
ALT723314
Servicing Brakes

Nov. 28, 2003
March 1, 2006
Page #
22
INFORMATION SHEET NO. LO#31

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.
Code No.
ALT723314
Servicing Brakes

Nov. 28, 2003
March 1, 2006
Page #
23
DIAGNOSIS
SELF TEST CODES
Code No.
ALT723314
Servicing Brakes

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March 1, 2006
Page #
24
PERFORMANCE TEST
Learners Name
Date:
Test Attempt
1st
2nd
3rd
Competency: Service Brake System

Directions:
OVERALL EVALUATION
Level
CALL INSTRUCTOR, ask Achieved
PERFORMANCE LEVELS
instructor
to assess
4 Can perform this skill without supervision and with initiative
and adaptability to problem situations.
your performance in the
following critical task
3 Can perform this skill satisfactorily without assistance or
supervision.
and performance criteria
below.
2 Can perform this skill satisfactorily but requires some
assistance and/or supervision.
You will be rate based on

the overall evaluation on
the right side.
1 Can perform parts of this skill satisfactorily, but requires

considerable assistance and/or supervision.
Instructor will initial level achieved.
PERFORMANCE STANDARDS
For acceptable achievement, all items should receive a Yes
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
Yes
No
N/A
replace
brake lines
5.
adjust emergency brakes linkage
6.
test the following ABS component

a.
b.
c.
d.
hydraulic unit
electrical system
wheel speed sensor
ECU
7.
adjust pedal free-play according to

specification
8.
proper use of tools and materials
Code No.
ALT723314
Servicing Brakes

Nov. 28, 2003
March 1, 2006
Page #
25
Learners 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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Code No.
ALT723314
Servicing Brakes

Nov. 28, 2003
March 1, 2006
Page #
26
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:
Learner has satisfied the above performance criteria.

Learners signature: .
Trainers signature: ..
Date: .
Code No.
ALT723314
Servicing Brakes

Nov. 28, 2003
March 1, 2006
Page #
27
Learning Outcome #2 - Diagnose brake system failure
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:

Date: .
Code No.
ALT723314
Servicing Brakes

Nov. 28, 2003
March 1, 2006
Page #
28
Learning Outcome #3 - Perform ABS component testing
3. Amperage draw is checked according to the required manufacturers
specification.
COMMENTS:

Date: .
Code No.
ALT723314
Servicing Brakes

Nov. 28, 2003
March 1, 2006
Page #
29
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.
ALT723314
Servicing Brakes

Nov. 28, 2003
March 1, 2006
Page #
30

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COMPETENCY BASED LEARNING

Service Brake System

NATIONAL CERTIFICATE LEVEL 2

COMPETENCY-BASED LEARNING MATERIALS

Service Clutch System

Service Differential and Front Axle

Service Steering System

14. Service Brake System

Service Suspension System

Overhauling Brake Systems

About this Competency Based Learning Material

Recognition of Prior Learning (RPL)

UNIT OF COMPETENCY : Service Brake System

Date: Developed Date: Revised

Service Brake System

Perform brake system preventive maintenance

Date: Developed Date: Revised

LEARNING EXPERIENCES / ACTIVITIES

Adjust brake clearance to specification

Technique in changing and filling fluid to

Steps and procedure in bleeding hydraulic

Adjust pedal free-play

ILO Learning Element Maintenance

Adjust emergency brakes linkage

Fabricate and replace brake lines.

Date: Developed Date: Revised

INFORMATION SHEET NO. LO#1-1

c. Remove rear brake drum. If the

2. Inspect Brake Lining

Date: Developed Date: Revised

4. Clean Brake Drum and Shoes

Date: Developed Date: Revised

Check fluid level and refilling

While tile pedal is depressed, loosen

Date: Developed Date: Revised

6. Keep on pumping the pedal until

Adjusting Pedal free Travel (with booster)

5. Screw in stop lamp switch until its

6. Be sure that the pedal stopper of the

Date: Developed Date: Revised

7. Slightly push the brake pedal with your

10. Tighten lock nut and measure again

11. Start engine and confirm if free play is

Emergency Brake/Parking Brake

Date: Developed Date: Revised

1. Set parking brake to a fully applied

2. Raise car and make sure its secure

3. Released parking brake, loosen

Date: Developed Date: Revised

5. Adjust adjusting nut until wheels turns

6. Check cables for fraying, breakage

7. Spray all exposed metals with

Date: Developed Date: Revised

8. Clean off threaded areas and make

9. Lower the vehicles and release

Fabricating and Replacing Brake Lines

Date: Developed Date: Revised

1. Use recommended steel tube size and

3. Use tube cutter to cut to required