BRAKES - AA1Car.comBrakes work in conjunction with Anti-Lock Brake Systems providing controlled steering during hazardous stopping situations. Brakes in conjunction with ... Brake

BRAKES

QUALITY FRICTION PRODUCTS FROM A NAME YOU TRUST

How is the Brake System Evolving?

Performing a Proper Diagnosis

Latest Repair Techniques andInstallation Recommendations

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A PROFESSIONAL TECHNICIAN’SGUIDE TO BRAKE SERVICE

Quality Friction Productsfrom a Name You Trust

Brake SystemOverview

Understanding theSafety Triangle™

Professional Technician’sRecommended Checklist

Inspection of Brake PadsConditions That

May Cause Noise

Inspection ofBrake Pads

Overheating Conditions

Inspection ofBrake Dust

Inspection of Brake PadsNormal vs. Excessive

Pad Wear Comparisons


Lack of Proper Lubrication

Inspection of Rotor andHydraulic System

Inspection ofBrake System Electronics

Brake Pads InstallationQuick Tips

Common Brake ShoeNoise Conditions

Brake Shoes InstallationQuick Tips

A Complete Lineof Stopping Solutions

The RightProduct Support

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BRAKE SYSTEM OVERVIEW

A TECHNICIAN’S GUIDE TO ASSIST WITH DIAGNOSIS AND INSPECTION

Brake PedalPosition Sensors

Yaw Rate Sensor

Steering WheelPosition Sensor

ABS Command Module

Collision Detector Sensors

Metering ValveCombination Valve

Proportioning Valve

DiscBrakes

DrumBrakes

PressureDifferential Switch

Master Cylinder

Brake FluidReservoir

Power Booster

FlexibleHydraulic Lines

Disc Brake RotorBrake Pad

Brake Pads Piston

ShimsPistonBootCaliper

SteelHydraulic Lines

Parking BrakeCable

Return Spring

Brake DrumBacking Plate

Brake FluidBleed Screw

Wheel Cylinder

Lever

Adjuster LeverSpring

PistonSeal

Shoe ShoeAdjusterCaliper

GuidePins

ParkingBrake

BrakePedal

IDENTIFYINGBRAKE SYSTEM COMPONENTS






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UNDERSTANDING THE SAFETY TRIANGLE™

INTERCONNECTED UNDERCAR PARTS THAT AFFECT A DRIVER’S ABILITY TO AVOID ACCIDENTS

STEERINGBrakes work in conjunction withAnti-Lock Brake Systems providingcontrolled steering during hazardousstopping situations.

Brakes in conjunction withStability Control Systems helpimprove vehicle balance and handlingduring evasive maneuvers.

STOPPINGFront and rear brakes work togetherto help your vehicle consistently stopunder various driving conditions.Modern Active Braking Systems can helpyou stop sooner in emergency situations.

STABILITY

WHAT IS THE SAFETY TRIANGLE™ INSPECTION?

The Safety Triangle™ Inspection checks critical interconnected system componentsthat control steering, stopping and stability. Going beyond tires and brakes to include

shocks, struts, springs, tie rod ends, ball joints and a host of other suspension andchassis parts, the Safety Triangle™ is vital to a driver’s ability to avoid accidents.

Just one worn part could diminish vehicle control and compromise safety.

The Safety Triangle™ Inspection is a three-part process duringwhich a professional technician (1) interviews the owner of the

vehicle, (2) evaluates the brake system balance during operation,and (3) physically evaluates the brake system components.






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PROFESSIONAL TECHNICIAN’S RECOMMENDED CHECKLIST

CUSTOMERS EXPECT QUIET, CLEAN, DEPENDABLE AND SAFE BRAKES

TEST DRIVECUSTOMER INTERVIEWHave you experienced any noises while braking?

- Grinding / Groan / High-pitched squeal

PHYSICAL INSPECTIONMechanical Components -Friction material, rotors, brake cables and installation hardware

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Hydraulic System -Master cylinder, calipers, wheel cylinders, hydraulic lines /hoses metering proportioning and pressure differential valvesand brake fluid

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Electronics -Wheel speed, yaw rate / rotational rate and collisionavoidance sensor(s )Steering wheel position sensor calibration,electronic brake control module codes, ABS relaysand tail light bulb / switchesBrake pedal position and wire wear sensors

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Have you felt any vibrations in the steering wheel,brake pedal or vehicle body while braking?

Does the brake pedal feel spongy,or have excessive travel?

Does the vehicle take longer to stop,or do you have to apply higher pedal pressurethan you used to?

Do any of your rims exhibit excessive brake dust?

Does vehicle pull to left or right while braking?

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• Evaluate the vehicle drive comparedwith customer’s interview responses

Check each wheel for equal brakingtemperature using infrared thermometer

Check for pull, pulsation and pedal feel

Are any advanced technologywarning lights illuminated?

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INSPECTION OF BRAKE PADS

CONDITIONS THAT MAY CAUSE NOISE

STEEL FRAGMENTSFrom Turned Rotor

… that was not cleaned prior to installation.

Each rotor must be washed with clear detergentliquid cleanser, in warm water.

GROOVED PAD SURFACECaused by Failing to Apply aFine, Non-Directional Finish

After Turning the Rotors

Resulting grooves can lead to noise eventsand / or increase stopping distance

GROOVES ON PAD EDGESGrooves on Pad Edge Indicate

Lack of Proper Rotor Preparation

Lack of proper rotor preparation leaveshard oxidation ( rust ) areas that wear awaythe edges of the pad. The resulting grooves

can lead to noise events.

Decreased pad-to-rotor surface contact areamay increase stopping distance.

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OVERHEATING CONDITIONS

GLAZED AND HEAT-CRACKEDFRICTION MATERIAL

OVERHEATED / DRAGGINGBRAKES


Excessive brake temperatures“Riding” the brake pedalHigh speed stopsUnbalanced braking effort fromfront-to-rear or side-to-sideFriction material contaminatedwith solvents or greaseHydraulic bindingMechanically bindingLack of down shifting /engine braking on steep gradesImproper friction material selectionfor braking conditions

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Excessively shiny and hardfriction material surfacecan result in glazing andpedal feel issues, likelyresulting in increasedstopping distances

Causes of glazing and uneven,“wavy” rotor surface:






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INSPECTION OF BRAKE DUST

COMMON BRAKE DUST CONDITIONS

BLACKBRAKE PAD DUST

Excessive wearof semi-metallic pads

and rotors

TANBRAKE PAD DUST

Excessive wearof ceramic pads

RUSTBRAKE ROTOR OR PAD DUST

Ferrous metal in brake dustfrom rotors and / or pads

oxidizes on wheels, causingwheel finish to be rust-colored

HEAT = WEAR = DUSTSOLUTION 1)CHECK FOR EQUAL BRAKING EFFORT ON ALL FOUR CORNERS VIA INFRARED THERMOMETER

SOLUTION 2)DUST CAN BE REDUCED BY

ENSURING THE PADSFIT PROPERLY

Visual symptoms include shinyedges, no lubricant, cracks in thepad surface from heat, and glazedfriction material from brake dragIndicates the brake pads wereforced into place, without lubricant

Proper preparation includes cleaningrust from tab contact surface and areasunderneath noise elimination clips

Pads should slide in by hand,with slight drag

Do not force pads into placewith tools such as a hammer,or a rubber mallet

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NORMAL vs. EXCESSIVE PAD WEAR COMPARISONS

EXCESSIVEInner Pad Wear

Causes:

NORMALFull Life Pad Wear

Even wear on both the innerand outer pad

If both wheel sets are in thiscondition, then brake systemis functioning normally andpads have run their useful life

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NORMALPad Wear

Even wear on both the innerand outer pad

If both wheel sets are in thiscondition, then brake systemis functioning normally

Technician should continuewith M.A.P. preventativemaintenance schedule

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EXCESSIVETapered Pad Wear

Causes:

EXCESSIVEOuter Pad Wear

Causes:


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Seized piston, pin or bushings

Limited movement of caliper;seized or not lubricated

Installation hardware and / orbushings not lubricated

• Binding of caliper usuallyfrom contamination orlack of lubrication oncaliper slides / pins

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Rust near installation hardwarebinds pad

Limited movement of caliper;seized or not lubricated

Installation hardware and / orbushings not lubricated






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LACK OF LUBRICANTBacking Plate / ShimShows Circular Wearfrom Piston Contact

Lubricate all pad-to-calipercontact areas, including:

Backing plate / shim, piston, tabs,spring clips and abutment area.

OVER-LUBRICATED /CONTAMINATION

Pad SurfaceLooks Greasy or Shiny

Caused by friction materialcontaminated with grease.

To resolve, use warm water and cleardetergent to clean friction material.

Make sure to handle new pads only withclean material during installation. 9


LACK OF PROPER LUBRICATION - MAIN CAUSE OF BRAKE NOISE

WHERE TO APPLY LUBRICANTTo avoid rotor contamination, do not apply an excessive amount of lubricant.

Apply an even amount of lubricant to areas of the backing plate that willtouch metal - including the shim and both sides of installation hardware.

Clean and lubricate slide pins on pin-type floating calipers.






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INSPECTION OF ROTOR AND HYDRAULIC SYSTEM

PEDAL FEEL CONCERNS: PULSATION, SPONGY, LOW / HIGH AND HARD PEDAL

CHECK HYDRAULIC SYSTEM

CHECK FOR ROTOR RUN-OUTMake sure hub surface is clean before mountingthe rotor

Solution:Apply vehicle manufacturer’s torque specsto lug nuts following recommended star pattern

Use a dial indicator to measure rotor run-out

Resolve excessive run-out by indexing rotor(Rotate 180º and re-check)

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ROTOR THICKNESS VARIATIONThickness variation is also called “parallelism”

Both sides of the rotor must be parallelto prevent pedal pulsations

Use a caliper to measure rotor thickness infour to twelve locations around the rotor’scircumference

Usually indicates scalloping of the rotor

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For leaks

For torn dust boots

Condition ofrubber hoses

Hydraulic issues can lead to uneven brakepad wear, pedal feel, noise and dust issues

Inspect:

Bleed air from hydraulic system

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Electronic bleeding is recommended on mostmodern systems

High points may require bleedingthrough line connections to completelyeliminate air from the system

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Condition of steel brake lines

For binding calipersand wheel cylinders(Open bleeder to determineif binding is due to internalhose damage)

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GRAPHING OFWHEEL SPEED SENSORThe Wheel Speed Sensor readingsshould be almost identical to eachother with no “drop-outs.”

Look for Wheel Speed Sensors that losetheir signal at a relatively higher speed thanthe others when coming to a complete stop.

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Steering Wheel Position Sensors often needto be recalibrated after steering componentshave been replaced or alignment work hasbeen performed.

If the Steering Wheel Position Sensoris out of calibration it can affect thestability control operation.

1) Inspect ABS fuses and relays

2) Perform voltage drop tests on grounds and power

3) Follow recommended diagnostic flow chart procedure

CALIBRATION OFSTEERING WHEELPOSITION SENSOR

WHAT TO INSPECT?Advanced electronics including active braking /collision avoidance are becoming more integrated intothe operation of the brake system, making it critical to inspectand repair any electrical issues.

Inspect brake / tail light operation

Inspect brake switch, parking brake switch, low fluid level warning switchand pressure differential switch

Replace worn wire wear sensors

Graph operation of: wheel speed sensor, brake pedal position sensor,yaw rate sensor, collision detection sensor(s )

To resolve brake system diagnostic trouble codes:

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• Ensure steering angle position sensor is calibrated

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INSPECTION OF BRAKE SYSTEM ELECTRONICS

ADVANCED ELECTRONICS






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BRAKE PADS INSTALLATION QUICK TIPS

HELP DELIVER THE BEST RESULTS AND MINIMIZE COMEBACKS

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Rotors should be replacedor resurfaced with a fine,

nondirectional finish.

Open bleeder and thencompress piston. Do not

hammer to set pads in place.

Inspect all components.Replace worn hardware,

including pad installation clips.

Check temperature of allfour brakes to ensure

balanced braking effort.

Wash rotor withclear detergent

liquid cleanser and warm water.

Torque lug nuts tomanufacturer specifications

using star pattern.

Do not touch orcontaminate

friction material.

High-speed break-in is NOT recommended!20 - 30 stops, 20 - 30 mph (32 - 48 kph)

leaving 30 seconds between stops.

Lubricate sliding surfaces,back of pad and

both sides of clips.






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COMMON BRAKE SHOE NOISE CONDITIONS

VISIBLE SIGNS OF INSTALLATION ISSUES

NO GAP • NO NOISENormal Operation

Inspect the drum-to-shoe contact area prior to installation.The arc of the brake shoe should match the arc of the drum surface.

A slight clearance at the leading and trailing edges of the frictionmaterial is acceptable, but the center contact should be snug.

CENTER GAP • NOISE ISSUESDrum Brake Groan

When the leading edge of the friction material contactsthe drum surface before the full friction contacts the drum,noise issues occur. Drum brake groan is a loud, low moan

produced at low vehicle speed, with moderate brake pressure.






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BRAKE SHOES INSTALLATION QUICK TIPS

HELP DELIVER THE BEST RESULTS AND MINIMIZE COMEBACKS

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Inspect the drum forout-of-round and

“bell-mouth” conditions.Drum may be replaced

or remove lip wearby refinishing.

Adjust shoesto drum.

Torque lug nutsusing star pattern.

Clean, inspectand lubricatebacking plate.

Inspect forfrozen or leakingwheel cylinders.

Inspect for leakingaxle seals.

Check temperature of all four brakesto ensure balanced braking effort.

High-speed break-in is NOTrequired or recommended!

Follow manufacturer’srecommendation.

Inspect andclean or replace

hardware, springsand adjuster.

Wash rotor withnon-detergent

(clear) liquid cleanserand warm water.

Do not touch orcontaminate

friction material.

Inspectparking brake

operation.

Press pivot pinsin with vise.

Do NOT use hammerto install pins!






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A COMPLETE LINE OF STOPPING SOLUTIONS

QUALITY BRAKES FROM A NAME YOU TRUST

CERAMICAND SEMI-METALLIC

FRICTION FORMULATIONS

PERFORMANCE-VERIFIEDFRICTION FORMULATIONS

BRAKE SHOES

BRAKE SHOESENGINEERED TO MATCH

OE SPECIFICATIONS

ENGINEERED FORHARD-WORKING TRUCKS,EMERGENCY, SEVERE USE

AND FLEET VEHICLES

U LT R A - P R E M I U M P R E M I U M






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THE RIGHT PRODUCT SUPPORT

For more information visit: www.monroebrakes.com

Monroe Brakes’ ASE-certified Technical Support Team will help you with answersto the most frequently-asked application, installation and friction questions.

Learn more about your coverage solution for today’s vehiclesFor technical assistance (for trade use only):

1 (800) 201-6506 M - F, 8:30 am - 5:30 pm EST

Monroe Brakes® Technical Support providesinvaluable brake pad technical traininginformation, as well as drum anddisc brakes training information.

If you are looking for answers to technicalquestions, the Monroe Brakes® CustomerService Department is just a phone call away.

FIND ANSWERS TO THE MOSTFREQUENTLY ASKED PRODUCTAND INSTALLATION QUESTIONS

TRAINING CLINICS•

Informative reference material identifying symptomsof brakes failure and corrective diagnostics.

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INFORMATIVE PRODUCT CATALOGSMaximize sales with accurate, industry-leadingpublications and convenient e-catalog.

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IN-DEPTH EDUCATIONAL PROGRAMS HELP SERVICE PROVIDERS RESOLVE FRICTION PROBLEMS

© 2015 Tenneco Automotive Operating Company Inc. Printed in USA TEN-0252-1015

Monroe Brakes provides ongoing professional trainingfor technicians nationwide, helping service providerseducate consumers about friction products.

Training DVDs Tech Talk / Website Support

E-Catalog Master Catalog

TECHNICAL SUPPORT MATERIAL






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Documents

BRAKES - AA1Car.comBrakes work in conjunction with Anti-Lock Brake Systems providing controlled steering during hazardous stopping situations. Brakes in conjunction with ... Brake