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Vehicle Brake System Common Faults and Maintenance Techniques
The braking system is one of the most critical safety components in a vehicle. A malfunction can lead to severe consequences if not addressed promptly. Common issues and their corresponding repair procedures for an automotive brake system are outlined below:
First, poor braking or complete failure.
1. Leaks or blockages in the brake lines (such as joints) can cause low brake fluid levels and reduced pressure, leading to ineffective braking. Regular inspection of the brake lines is essential to detect leaks, top up the brake fluid, and clear any obstructions.
2. Air entering the brake system can cause a spongy pedal feel. This often happens when the brake fluid overheats and vaporizes, creating air bubbles that compress during braking, reducing stopping power. During maintenance, bleed the brake system to remove air and refill with fresh brake fluid as needed.
3. Improper brake shoe-to-drum clearance can result in excessive travel of the master cylinder piston, causing delayed response and reduced braking efficiency. Adjust the gap according to manufacturer specifications by using a flathead screwdriver to toggle the ratchet mechanism from the adjustment hole, ensuring full contact before setting the correct clearance.
4. Poor contact between the brake drum and friction linings due to deformation or out-of-roundness can reduce friction. If this occurs, the drum should be machined or replaced if the diameter exceeds 220mm.
5. Contamination of the brake linings with oil or water significantly reduces the coefficient of friction. Clean the pads with gasoline and heat them with a torch to remove oil. For water-soaked pads, continuous braking can help dry them out.
6. Damage to the master cylinder or wheel cylinders can cause internal leakage and loss of pressure. These parts should be inspected and replaced if necessary.
Second, uneven braking.
1. Uneven braking time on both sides of the axle may be caused by mismatched brake gaps or contact areas. Re-adjusting the brake shoes and dressing the friction linings can help achieve balanced braking.
2. Differences in braking force on each side can cause the car to pull to one side. This could be due to oil leaks, contaminated pads, or uneven tire pressure. Cleaning the pads, adjusting tire pressure, and repairing leaks can resolve the issue.
3. Sudden drifting while driving without applying the brakes may indicate suspension or frame misalignment. Inspect and repair the affected components to restore proper alignment.
4. Braking causing the wheels to slide sideways might be due to uneven surface roughness or air in one line. Check for blockages or air in the system and fix accordingly.
5. Uneven tire pressure can also lead to lateral drift. Ensure both tires are inflated to the recommended pressure.
6. Other causes include incorrect wheel alignment or uneven tire wear. Address these by adjusting the alignment or replacing worn tires.
Third, unusual noises during braking.
1. An out-of-round brake drum can create a knocking sound when the shoes make contact. Machining the drum to specifications and checking its balance will help eliminate the noise.
2. Smooth surfaces on the brake linings can generate friction noise, especially under high pressure. Remove foreign objects and sand the linings to improve contact area.
3. Severe wear on the brake linings can lead to grooves and irregular shapes, resulting in noise. Replace the linings and ensure the brake backing plate is properly aligned.
4. Damaged front wheel bearings with pits or cracks can produce abnormal sounds. Replace the bearings to restore quiet operation.
Fourth, brake fade due to overheating.
1. Excessive brake shoe-to-drum contact can cause prolonged friction, leading to overheating and reduced braking performance. Adjust the brake clearance to allow full release.
2. If the brake pedal doesn't fully return, it may cause continuous friction. Check and adjust the pedal position accordingly.
3. A weakened return spring can prevent the brake shoes from releasing properly, causing overheating. Replace the spring if necessary.
Fifth, parking brake failure.
Common issues include corroded cables, broken springs, or stretched cable jackets, which prevent the parking brake from engaging properly. Inspect the cables, ensure smooth operation, and replace damaged parts as needed. When testing, apply 196N of force to the parking brake lever, and it should move 5–7 teeth to engage fully. If more than 7 teeth are required, the gap may be too large or the cable stretched—adjust accordingly.