Drum Brake Inspection, Maintenance, and Service Drum Brake
Contents
1. 377 suausiignd aljseg pue sauor Drum Brake Inspection Maintenance and Service Student intern information Name o Md ate Class Vehicle used for this activity Year___ CO Make ran pre Ale AP mierninnPrAA Model Odometer__ __ CS lt 2 VIN Time off i i i CDX Tasksheet 2008 NATEF 2008 NATEF TAEA Ramga eet Roenes Ramee Beaty oe Time on e Diagnose poor stopping noise vibration pulling grabbing C706 P 1 dragging or pedal pulsation concerns determine necessary action e Remove clean inspect and measure brake drums deter C800 P 1 Total time mine necessary action e Refinish brake drum measure final drum diameter C626 e Inspect and install wheel cylinders C707 e Pre adjust brake shoes and parking brake install brake C801 drums or drum hub assemblies and wheel bearings 5C1 3 OY 5C3 e Remove clean and inspect brake shoes springs pins clips C248 5C4 P 1 levers adjusters self adjusters other related brake hard ware and backing support plates lubricate and reassemble 5C5 ICO Ci e Install wheel torque lug nuts and make final checks and C251 5 P adjustments Recommended Resource Materials Materials Required e CDX Automotive program e Vehicle with drum brake concern e CDX eTextbook e Manufacturer specific tools depending on the e Technical service bulletins shop manuals and concern any other information applicable to the specific Vehicle lifting equipme2. 5 6 7 8 Following the manufacturer s procedure reassemble the brake assembly shoes springs and hardware Are the springs seated correctly Yes No Circle one Does the self adjuster operate properly Yes No Circle one List any necessary action s 9 Have your supervisor instructor verify satisfactory completion of this procedure any observations found and any necessary action s recommended Performance Rating CDX Tasksheet Number C248 2008 NATEF Reference Number 5C4 La m m E m O 1 2 3 4 Supervisor instructor signature gt Date r Xi Pre adjust brake shoes and parking brake install brake drums or drum hub ua assemblies and wheel bearings C801 5C6 a 1 If this vehicle uses serviceable wheel bearings see the Wheel Bearing Service page 55 tasksheet and clean inspect service reinstall and adjust them according to manufacturer s procedure 2 Install the brake drum a Does the brake drum turn without excessive drag Yes No Circle one Total time b If equipped with adjustable wheel bearings are they adjusted properly Yes No Circle one The brakes may need air bled out of the wheel cylinders if they were removed from the vehicle If they were consider bleeding all wheel cylinders once all drums and calipers are back in place Failure to have all drums and calipers installed could cause damage to the wheel cylinders calipers brake shoes and pads Ask your instructor if you are unclear about thi
3. Primary in mm Secondary in mm e Parking brake adjustment specification f Lug nut torque ft lbs Nm g Draw lug nut torque pattern 3 With instructor permission test drive the vehicle to verify the concern Be sure to follow all shop policies regarding test drives List your observations The rest of this task is performed at the end of the drum brake service Please refer to page 38 for the completion of this task all 290 gt TASK Remove clean inspect and measure brake drums determine necessary action C800 5C2 1 Remove the brake drum following the service manual procedure being careful not to disturb any brake dust Clean the brake drum using equipment procedures for dealing with asbestos dust 2 Inspect the drum a Measure and record the diameter in mm b Measure and record the amount of out of round in mm tea Measure in at least three places equally spaced around the drum UO dw 440 aw 34 Drum Brake Inspection Maintenance and Service Jones and Bartlett Publishers LLC NOT FOR SALE OR DISTRIBUTION Jones and Bartlett Publishers LLC 971 Ssaysi qnd 9 Jeg pue ssuor 3 4 Performance Rating c Hot spots Yes No Circle one d Cracks Yes No Circle one e Other defects List if found Based on your observations measurements determine any necessary action s Have your supervisor instructor verify satisfactory completion of this procedure any observations found and a
4. ng thickness Primary in mm Secondary in mm b Inspect and clean hardware i Springs Damaged Missing Weak OK Circle one ii Pins Damaged Missing OK Circle one Drum Brake Inspection Maintenance and Service 35 Jones and Bartlett Publishers LLC NOT FOR SALE OR DISTRIBUTION iii Levers and adjusters Damaged Missing OK Circle one iv Backing plate Damaged Worn OK Circle one v Other hardware Damaged Missing OK Circle one 3 Determine any necessary action s 4 Have your instructor initial to verify condition of hardware The rest of this task is performed at the end of the drum brake service Please refer to page 37 for the completion of this task ueo PST inspect and install wheel cylinders C707 5C5 1 Remove the wheel cylinder following the service manual procedure to prepare for inspection uo awl X 93 1413 To prevent twisting the brake line it is common practice to loosen the brake line fitting before unbolting the wheel cylinder 40 oll L 2 Disassemble clean and inspect the wheel cylinder for damage wear or missing pieces a Bore Damaged OK Circle one b Pistons Damaged Missing OK Circle one c Seals Damaged Missing OK Circle one d Dust boots Damaged Missing OK Circle one e Spring s Damaged Missing OK Circle one 3 List any necessary action s 4 Have your supervisor instructor inspect the disassembled wheel cylinder and determine whether it can be rebuilt or whe
5. nt vehicle or components you are working on Asbestos removal equipment Class notes e Drum brake micrometer e Brake spring tools e Micrometer or dial caliper e Flare nut wrench to fit brake line fitting e Brake spoon Some Safety Issues to Consider e Diagnosis of this fault may require test driving the vehicle on the school grounds or on a hoist both of which carry severe risks Attempt this task only with full permission from your supervisor instructor and follow all the guidelines exactly e Caution Brake dust may contain asbestos which has been determined to cause cancer when inhaled or ingested Treat all brake dust as if it contains asbestos and use OSHA approved asbestos removal equip ment Do not allow brake dust to become airborne by using anything that would disturb the dust Also wear protective gloves during this procedure and dispose of or clean them in an approved manner Lifting equipment such as vehicle jacks and stands vehicle hoists and engine hoists are important tools that increase productivity and make the job easier However they can also cause severe injury or death if used improperly Make sure you follow the manufacturer s operation procedures Also make sure you have your supervisor instructor s permission to use any particular type of lifting equipment Drum Brake Inspection Maintenance and Service 33 Jones and Bartlett Publishers LLC NOT FOR SALE OR DISTRIBUTION e Always wear the correct protec
6. ny necessary action s recommended CDX Tasksheet Number C800 2008 NATEF Reference Number 5C2 La La a a O 1 2 B 4 Super visor imstruetomsrpmaccres IW NIN EMR RE OAR VN IIND IISI Date Refinish brake drum measure final drum diameter C626 5C3 iat Using the correct equipment and procedure refinish the brake drum to within allowable tolerances Measure the final drum diameter and note your findings here in mm Time on Calculate the amount of material removed from the surface of the drum in mm Does the drum meet specifications to be safely put back into service Yes No Circle one KR WN m Performance Rating a Why or why not Total time Have your supervisor instructor verify satisfactory completion of this procedure any observations found and any necessary action s recommended CDX Tasksheet Number C626 2008 NATEF Reference Number 5C3 a l a La a O 1 2 3 4 Supervisor instructor signature On C attle ANLE Remove clean and inspect brake shoes springs pins clips levers 1 2 adjusters self adjusters other related brake hardware and backing ui support plates lubricate and reassemble C248 5C4 ae Clean brake shoes hardware and backing plates using equipment and procedures for dealing with asbes tos dust Disassemble the brake shoes and hardware from the backing plate being careful not to lose any parts and remembering how they go back together Total time a Measure lini
7. s 3 Have your supervisor instructor verify satisfactory completion of this procedure any observations found and any necessary action s recommended Performance Rating CDX Tasksheet Number C801 2008 NATEF Reference Number 5C6 a a a a a O 1 2 3 4 Supervisor instructor signature s aattle Drum Brake Inspection Maintenance and Service 37 Jones and Bartlett Publishers LLC NOT FOR SALE OR DISTRIBUTION gt G6ines and par Install wheel torque lug nuts and make final checks and adjustments C251 5C7 1 Draw the lug nut torque pattern for this vehicle UO awl Wo aw 2 Install the wheel s place lug nuts on studs with the proper side facing the wheel and torque them to proper torque NOTE gt If in doubt about which way the nuts should face ask your instructor 3 What torque did you tighten the lug nuts to ft lbs Nm 4 Reinstall any wheel covers that have been removed 5 Check to see that the brake master cylinder has the proper amount of brake fluid in it a Is it at the proper level Yes No Circle one b If no refill with the proper fluid 6 Check the backing plates for any leaks or loose fasteners 7 Have your supervisor instructor feel brake pedal application and determine whether a test drive is neces sary to final adjust brakes and verify satisfactory operation of brakes Performance Rating CDX Tasksheet Number C251 2008 NATEF Reference Number 5C7 O 1 2 3 4 Supervisor instruc
8. ther it needs to be replaced a Rebuild Replace Circle one then initial 5 If the wheel cylinder can be reused rebuild it preferably with new seals and dust boots 6 Reinstall the wheel cylinder on the backing plate a2 It is usually best to start the brake line fitting into the wheel cylinder before bolting the cylinder down This will allow the threads of the brake line fitting to align with the threads in the wheel cylinder preventing cross threading of the parts 7 Have your supervisor instructor verify satisfactory completion of this procedure any observations found and any necessary action s recommended Performance Rating CDX Tasksheet Number C707 2008 NATEF Reference Number 5C5 O 1 2 3 4 Supervisor instructor signature COD atte 36 Drum Brake Inspection Maintenance and Service Jones and Bartlett Publishers LLC NOT FOR SALE OR DISTRIBUTION Jones and Bartlett Publishers LLC 377 suaysiiqnd 412g pue sauor Ari EC248 5C4 Continued Remove clean and inspect brake shoes springs pins clips Time off levers adjusters self adjusters other related brake hardware and backing support plates oe lubricate and reassemble from page 35 36 ae an sles Many vehicles use a primary shoe toward the front of the vehicle and a secondary shoe toward the rear of the vehicle Refer to the manufacturer s specifications to install the shoes springs and hardware re otai time correctly
9. tive eyewear and clothing and use the appropriate safety equipment as well as fender covers seat protectors and floor mat protectors e Make sure you understand and observe all legislative and personal safety procedures when carrying out practical assignments If you are unsure of what these are ask your supervisor instructor Performance Standard O No exposure No information or practice provided during the program complete training required 1 Exposure only General information provided with no practice time close supervision needed additional training required 2 Limited practice Has practiced job during training program additional training required to develop skill 3 Moderately skilled Has performed job independently during training program limited additional training may be required 4 Skilled Can perform job independently with no additional training aul 2 0 Ari Diagnose poor stopping noise vibration pulling grabbing dragging or pedal pulsation concerns determine necessary action C706 5C1 1 List the drum brake related customer complaint concern UO awl 40 awil 2 Research the description and operation of the brake system for this vehicle in the appropriate service manual Also research the drum brake diagnostic procedure and removal installation procedures a List the possible cause s of the complaint concern b Maximum drum diameter in mm c Maximum drum out of round in mm d Minimum lining thickness
10. tor signature Date Stam een ae1 C706 5Ci1 Continued Diagnose poor stopping noise vibration pulling grabbing dragging or pedal pulsation concerns determine necessary action from page 34 4 Reflecting back on this job list the causes of the customer concern as listed at the beginning of this tasksheet UO awl JO aul l l 5 Document the correction s required to fix the customer concern 6 Did you repair the vehicle Yes No Circle one 7 List any additional necessary action s 8 Have your supervisor instructor verify satisfactory completion of this procedure any observations found and any necessary action s recommended Performance Rating CDX Tasksheet Number C706 2008 NATEF Reference Number 5C1 O 1 2 3 4 Supervisor instructor signature Date 38 Drum Brake Inspection Maintenance and Service Jones and Bartlett Publishers LLC NOT FOR SALE OR DISTRIBUTION Jones and Bartlett Publishers LLC
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