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FACULTY OF ENGINEERING TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING

TECHNOLOGY

MAINTENANCE AND SERVICING SUSPENSION

AND BRAKE SYSTEM

MMT 11204- AUTOMOTIVE WORKSHOP PRACTICE

UR6525001- BACHELOR OF TECHNOLOGY IN AUTOMOTIVE

ADAM LUQMAN BIN RAHMAT

221541897
CONTENTS

NO. THINGS PAGE

1. INTRODUCTION 1-10
-CAR BRAKE TYPES
-HYRAULIC BRAKES
-POWER BRAKES
-BRAKE SYSTEM COMMPONENT
2. MAINTENANCE AND SERVICING 11-15
-BRAKE PAD
-WHEEL CYLINDER
-BRAKE CALIPER
3. SUGGESTIONS 15-16

4. CONCLUSION AND REFERENCE 16

INTRODUCTION SUSPENSION AND BRAKE SYSTEM
Suspension system is system of tires, tires air, spring, shock absorbers, and linkages that
connects a vehicle to wheels and allow motion between these two. These are the main
components in suspension system. Main function of the suspension system is to isolate the body
of the vehicle from shocks and vibrations generated due to irregularities on the surface of roads.

Brake system in a vehicle is designed to slow down or stop the vehicle by applying
friction to the wheels. It is a critical safety feature that allows the driver to control the speed of
the vehicle and bring it to a stop in a safe and controlled manner. The main component in brake
system is brake pedal, master cylinder, brake lines, caliper or wheel cylinder, rotor or drums and
anti- lock brake system (ABS) in modern car nowadays

INTRODUCTION BRAKE SYSTEM

A brake is a mechanical device designed to restrain motion by absorbing energy from a
moving system usually by the means of friction. It is used to slow or stop a moving vehicle,
wheels, axle, etc. The braking system is a complication device with a lot of parts, but its working
seems very easy. After all, pressing a single pedal will activate all brakes on the four wheels. The
slowing down is achieved by hydraulic fluid, which is often bleed to get the best performance of
the breaking.
Car brakes are designed to slow and stop a vehicle by transforming kinetic (motion)
energy into heat energy. As the brake linings contact the drums/rotors they create friction which
produces the heat energy. The intensity of the heat is proportional to the vehicle speed, the
weight of the vehicle, and the quickness of the stop. Faster speeds, heavier vehicles, and quicker
stops equal more heat.
When press down on the brake pedal, a connected lever pushes a piston into the master
cylinder, which is filled with hydraulic fluid. That hydraulic fluid gets squirted along a system of
pipes into other, wider cylinders positioned next to the brakes on each wheel

CAR BRAKE TYPES

Automotive industry keep evolving days by days and make car manufacturers make a
new evolution to brake system. There are few brake system and power brakes that will explain
down here.

1 DISC BRAKES

Brake rotors of disc brakes rotate with the wheels, and brake pads, which are fitted to the
brake calipers, clamp on these rotors to stop or decelerate the wheels. The brake pads pushing
against the rotors generate friction, which transforms kinetic energy into thermal energy.

2 DRUM BRAKES

A drum brake is a brake that uses friction caused by a set of shoes or pads that press
outward against a rotating cylinder-shaped part called a brake drum.
 The term drum brake usually means a braking system in which shoes press on the inner
surface of the drum. When shoes press on the outside of the drum, it is usually called a clasp
brake. Where the drum is pinched between two shoes, similar to a conventional disc brake, it is
sometimes called a pinch drum brake, although such brakes are relatively rare. A related type
called a band brake uses a flexible belt or "band" wrapping around the outside of a drum.

3 HYDRAULIC BRAKES

-The principle behind any hydraulic system is simple: forces that are applied at one
point are transmitted to another point by means of an incompressible fluid. In brakes we
call this brake fluid of which there are a few different varieties, but more on that later.

-As is common in hydraulics the initial force which is applied to operate the system
is multiplied in the process. The amount of multiplication can be found by comparing the
sizes of the pistons at either end. In braking systems for example, the piston driving the
fluid is smaller than the pistons operating the brake pads therefore the force is multiplied
helping you to brake easily and more efficiently.

POWER BRAKE TYPES

1 AIR BRAKES

Air brakes on heavy vehicle like trucks work using compressed air. Air is pressurized by
an engine-mounted compressor. The air compressor then pumps the air into the air storage tanks,
which store the compressed air until it’s needed.
 Air pressure is used to apply the service brakes and release the parking brake. There are
multiple air circuits in the system. The parking brake engages by spring force in the parking
brake portion of the spring brake chamber when the air pressure in the chamber is released.

This also allows the parking brake to be used as the emergency brake system. If air
pressure was to drop too low, the force exerted by the spring in the chamber will be able to
overcome the force exerted by the air on the diaphragm and apply the brakes on all wheels.

2 AIR HYDRAULIC BRAKES

Air hydraulic brakes work by using compressed air to apply force to a piston in a brake
cylinder. The piston then pushes against a brake pad or shoe, which presses against a rotating
drum or disc to slow or stop the vehicle. The compressed air is supplied by an on-board air
compressor and stored in an air tank. When the driver presses the brake pedal, it activates a valve
that releases the compressed air from the tank and into the brake cylinder, which causes the
piston to move and apply the brakes. The compressed air also actuates the brake on the other
wheel of the vehicle through the brake pipe. This type of braking system is commonly used in
large commercial vehicles such as trucks and buses.

HOW ITS WORK?

NORMAL BRAKING
-The system works by combining elements of an air brake and a hydraulic brake.
-It has a special type of power cylinder that contains a hydraulic cylinder and an air
cylinder in tandem.
-While both of these cylinders have pistons, the important thing to note is that the pistons
are not the same size. the air piston is greater in diameter compared to the piston for the
hydraulic cylinder.
-The air piston is greater in diameter compared to the piston for the hydraulic cylinder.
-What does this mean? This means that there is more hydraulic pressure compared to air
pressure during normal breaking, so when the pedal is pressed, the valve opens and releases the
pressure, which causes braking to occur.
HARD BRAKING
-The valve movement when is different depending on how hard the brake pedal is
pressed.
-When heavier pressure is applied to the brake, there is more valve movement.
-Because of the increased valve movement, a greater amount of pressure is released into
the power cylinder, causing stronger and faster braking.

3 VACCUM BRAKES

Vacuum Braking System is one of the types of braking system, were mostly used in
railway locomotives in the mid 1860's before the invention of Air Brakes. Railway locomotives
were used Vacuum brakes instead of air brakes. Vacuum Brakes mainly consists of Brake pipes,
Brake Cylinder, and Vacuum Reservoir. The Vacuum pump in Vacuum Brake System creates
vacuum in the brake pipe; and the brake cylinder uses the vacuum reservoir for applying the
brakes.
When we release the brake pedal, the internal vacuum port allows engine vacuum to flow
from the check valve of equal vacuum on both sides of the diaphragms.
When we apply brakes, the brake pedal moves forward to close the vacuum port and it
allows to open the air inlet valve. The backside of the diaphragm from the vacuum source is
blocked by this action and simultaneously, filtered atmospheric air pressure passes through the
air inlet valve to the diaphragm backside.

4 ELECTRIC BRAKES
 Electric brakes, also known as electric drum brakes or electric trailer brakes, are a type of
braking system that uses an electric motor to apply the brakes. When the driver presses the brake
pedal, it sends a signal to the control module, which activates the electric motor. The motor then
turns a gear or cam that pushes the brake shoes or pads against the drum or rotor, slowing or
stopping the vehicle. Electric brakes can be used as the sole braking system.
Electric brakes are commonly used in trailers, such as boat trailers, horse trailers, and
utility trailers, as well as some recreational vehicles, as they are easy to install and less complex
than other braking systems. They also have better brake control which is essential for safety. In
addition, electric brakes are less affected by weather conditions, which makes them more reliable
and consistent.
CAR BRAKE PARTS
The brake system is composed of several different components that work together to slow
and stop the vehicle.

1 BRAKE PEDAL

-The brake pedal is connected to the brake booster, which amplifies the force applied by
the driver's foot. The brake booster uses a vacuum, or in some cases a hydraulic actuator, to
multiply the force applied to the brake pedal. This allows the driver to apply the brakes with less
effort and provides a more consistent pedal feel.
-When the driver presses the brake pedal, it activates the brake master cylinder, which
converts the force into hydraulic pressure. The hydraulic pressure is then sent through the brake
lines to the brake calipers or wheel cylinders. These components then press the brake pads or
shoes against the rotors or drums, slowing or stopping the vehicle.
2 MASTER CYLINDER
 It is responsible for converting the force applied by the driver's foot on the brake pedal
into hydraulic pressure. This pressure is then sent through the brake lines to the brake calipers or
wheel cylinders, which then press the brake pads or shoes against the rotors or drums to slow or
stop the vehicle.
It is a sealed cylinder that contains a piston and two fluid reservoirs, one for the front
brakes and one for the rear brakes. When the brake pedal is pressed, the piston inside the master
cylinder moves, forcing brake fluid out of the reservoir and into the brake lines.
Most commonly in two-piston or one-piston designs. A two-piston master cylinder is split
into two circuits, one for the front brakes and one for the rear brakes. A one-piston master
cylinder is used in vehicles with drum brakes in the back, and it pushes the brake shoes against
the drums using a single circuit.

3 BRAKE LINES

Brake lines are typically made of steel or a reinforced rubber material. Steel brake lines
are more durable and resistant to corrosion, but they are also more rigid and can be more prone
to leaks if they are damaged. Rubber brake lines are more flexible and less prone to leaks, but
they can be more susceptible to deterioration and cracking over time.
The brake lines are connected to the master cylinder at one end and the brake calipers or
wheel cylinders at the other. They are typically located near the wheels and run along the frame
or suspension of the vehicle. When the brake pedal is pressed, the master cylinder sends brake
fluid through the brake lines to the calipers or wheel cylinders. The calipers or wheel cylinders
then use the brake fluid to apply pressure to the brake pads or shoes, which press against the
rotors or drums to slow or stop the vehicle. Any issues with the brake lines, such as leaks or rust,
should be addressed by a qualified technician to ensure safe driving. Additionally, brake lines
should be checked periodically for signs of wear, and should be replaced if they are damaged or
corroded.
4 BRAKE CALIPERS
 There are two main types of brake calipers: fixed and floating. Fixed brake calipers have
the pistons on one side and are bolted to the knuckle. Floating brake calipers have the pistons on
both sides and are mounted to the knuckle using sliding pins. This allows the caliper to move and
adjust as the pads wear, which helps to ensure consistent braking performance over time.
Brake calipers are also available in different designs such as single-piston, dual-piston,
and four-piston, which refers to the number of pistons in the caliper. Single-piston calipers are
most commonly used on vehicles with drum brakes in the back, while dual-piston calipers are
more common on vehicles with disc brakes on all four wheels. Four-piston calipers are mostly
used in high-performance vehicles or vehicles that need a higher braking force.

5 ROTOR AND DRUMS

A rotor is a circular disc that is typically made of cast iron or steel and is located near the
wheel of a vehicle. Rotors are typically used in disc brake systems and are commonly found on
modern vehicles. When the brake pedal is pressed, the brake pads clamp down on the rotor,
which slows or stops the vehicle. Rotors are typically thicker than drums and are designed to
dissipate heat generated by the braking process, which helps to prevent warping and prolong
their life.
Drums, on the other hand, are typically cylindrical in shape and are located inside the
wheel of a vehicle. Drums are typically used in drum brake systems, which are more commonly
found on older vehicles. When the brake pedal is pressed, brake shoes press against the drum
from the inside, which slows or stops the vehicle. Drums are typically thinner than rotors and are
not as efficient in dissipating heat which makes them more prone to wear and fading.
Both rotors and drums are critical components of a vehicle's braking system and must be
maintained in good condition to ensure proper braking performance. Any issues with the rotors
or drums, such as warping, cracking or excessive wear, should be addressed by a qualified
technician to ensure safe driving. Additionally, rotors and drums should be checked periodically
for signs of wear, and should be replaced if they are damaged or worn out.

6 BRAKE PAD AND SHOES

-Brake pads are typically used in disc brake systems and are made of a composite
material, such as ceramic, semi-metallic or organic. They are located inside the caliper and press
against the rotor when the brake pedal is pressed. Brake pads are designed to be durable, heat
resistant and provide a consistent level of friction. They come in different compounds such as
ceramic, semi-metallic, and organic. Ceramic pads are quiet, clean and long lasting, semi-
metallic pads are more durable and better for high performance and heavy loads, while organic
pads are quieter and less aggressive.
-Brake shoes, on the other hand, are typically used in drum brake systems and are made
of a similar composite material. They are located inside the brake drum and press against the
drum when the brake pedal is pressed. Brake shoes are designed to be durable, heat resistant, and
provide a consistent level of friction.

7 WHEEL CYLINDER
 -A wheel cylinder is a component of drum brake systems. It is located inside the brake
drum and is responsible for pushing the brake shoes against the drum when the brake pedal is
pressed.
-The wheel cylinder is a small cylindrical device that contains one or more pistons. When
the brake pedal is pressed, brake fluid is sent from the master cylinder to the wheel cylinder,
which pushes the pistons outwards. This causes the brake shoes to press against the drum,
slowing or stopping the vehicle.
-The wheel cylinder is designed to be durable and withstand the high temperatures and
pressures generated by the braking process. It is a relatively simple and inexpensive component,

8 BRAKE FLUID

There are several different types of brake fluid, each with different properties and uses.
The two most commonly used types of brake fluid are DOT 3 and DOT 4.
DOT 3 brake fluid is a glycol-based fluid that is suitable for use in most vehicles. It has a
low wet boiling point and is hygroscopic, meaning it absorbs moisture from the air over time.
This can lower the boiling point of the fluid and cause a spongy brake pedal, so it is
recommended to be changed every 2 years or so.
DOT 4 brake fluid is also a glycol-based fluid, but it has a higher wet boiling point than
DOT 3. It is also hygroscopic and should be changed at the same intervals as DOT 3. It's
recommended for vehicles that are driven in harsh condition such as high temperatures or heavy
loads.

9 BRAKE ECU
 Its responsible for controlling and coordinating the various components of the brake
system, including the brake pedal, master cylinder, and brake calipers or wheel cylinders.
-The brake ECU is typically a small computer that is located in the vehicle's electrical
system. It receives input from sensors, such as the brake pedal position sensor and the wheel
speed sensor, and uses this information to control the brake system. when the driver presses the
brake pedal, the brake ECU receives a signal from the pedal position sensor and sends a signal to
the master cylinder to activate the brakes.
-The brake ECU also interfaces with other systems in the vehicle, such as the ABS (Anti-
lock Braking System) and the EBD (Electronic Brake-force Distribution) system. It uses the
input from these systems to adjust the brake pressure and prevent wheel lockup, improving
braking performance and stability.
MAINTENANCE AND SERVICING
1. BRAKE PAD

SYMPTOMS
-When driving, and when to slow down the car, its need long distance to stop and not
effectively to stop the car right away and trigger warning light appear on the dashboard for a car
that have the sensor.

FAULT
-Improper installation to the brake pad
-Excessive wear

SERVICING
1. Remove the slider bolt
2. Flip the brake caliper up

3. Slide out the old brake pads

4. Replace the retaining clips

5. Apply the grease to the clips of the new brake pads to keep them from squeaking,
6. Put new brake pads on
 7. Push the brake caliper pistons using special tools

8. Monitor the brake fluid level

9 Reposition the caliper reinstall the slider bolt
10. Test drive to make sure everything is good
2 WHEEL CYLINDER

SYMPTOMS
-When step on the brake pedal to slow down the vehicle, the brake response become poor
and not braking properly and brake fluids seal leaks and clearly visible at the wheel cylinder.
FAULT
-Wear and tear. When use it for long times, wheel cylinders may leak and not function
-Lack of maintenance. Wheel cylinder become full with brake dust and unknown things.

SERVICING
1. Remove the drum cover
2. Remove the retainer springs
3. Remove the brakes line

4. Remove the brake wheel cylinder bolts on the back of the wheel hub
5. Remove the broken wheel cylinder and old brake shoes

1
6. Clean rear and interior of rear hub with brake cleaner.

7. Install the new brake shoes

8. Install the new wheel cylinder
 9. Tighten the bolt behind the wheel cylinder, connects back the brake line, put back the
retainer springs and drum.
10. Bleed the brake to remove air from the brake lines and test drive.

3 BRAKE CALIPER

SYMPTOMS
-Hear abnormal noises when braking, uneven brake pads use and some vibration during
braking.

FAULT
-For long time using cars, the caliper seals and piston become damage and leaks
-Caliper not properly installed and leads to make the caliper broken faster
-Brake pads to thin and make the caliper malfunctions

SERVICING
-Locate the brake caliper and use a C-clamp or brake tool to compress the brake pads
against the rotor.
-Remove the caliper bolts or pins that hold the caliper to the steering knuckle or spindle.
-Carefully remove the caliper from the brake rotor. Be sure to support the caliper with a
wire or bungee cord to prevent damage to the brake hose.
-Remove the brake pads from the caliper.
-Clean the caliper and the mounting surface with brake cleaner and a wire brush.
-Inspect the caliper and the caliper guide pins for wear or damage. Replace any damaged
parts.
-Install the new brake pads into the caliper.
-Carefully place the caliper onto the brake rotor and reattach it to the steering knuckle or
spindle using the bolts or pins.
 -Release the brake tool or C-clamp and check the brake pedal for proper operation.
-Once calipers are installed, bleed the brake system to remove any air that may have
entered the brake lines.
-Finally, test drive the vehicle to make sure the brakes are working properly.

SUGGESTIONS
BRAKE PAD
-Brake pads manufacturer can develop using materials like ceramic to make the brake
pad and can do some material mixture like ceramic and metallic mixture to provide balance of
braking performance and can use for long term.

WHEEL CYLINDER
-Wheel cylinder manufacturers can use latest technology to make a sealed wheel cylinder,
it can become maintenance-free and no need to regularly to changes fluid
-Wheel cylinder also can be made by stainless steel because steel more durable, sustain
and can be use for a long term.

BRAKE CALIPER
-Brake caliper manufacturer can develop an new style of brake caliper like using
materials like ceramic to built new caliper because ceramic can highly sustain high temperature
heat and can be use for a long terms condition
-This caliper also can be a floating caliper. The caliper can move freely in the bracket that
can reduce wear of rotor and pads and improve braking performance

CONCLUSION

In conclusion, the braking system in automobiles is very important and essential as it

prevents the device from moving when required. There have been many recent developments in
brake technology that may improve the performance and durability of the brake system. These
include ceramic composite materials for calipers and wheel cylinders, low-friction coatings,
integrated caliper-wheel cylinder designs, electromechanical systems, smart brake calipers, and
four-piston or six-piston calipers. However, these are new technologies and have not yet been
widely adopted.
 -It is important to note that regular maintenance and inspection is essential to ensure that
the brake system is in good condition and working properly. This includes checking the brake
pads or shoes for wear, checking the brake fluid levels, and inspecting the brake lines, hoses, and
calipers for leaks or damage.
REFERENCE

https://www.youtube.com/watch?v=tRGGL3uhgjg
https://www.youtube.com/watch?v=qJDq68m4NTM
https://www.howacarworks.com/basics/how-the-braking-system-works
https://www.tiresplus.com/blog/brakes/types-of-vehicle-brakes/
https://www.carparts.com/blog/bad-brake-caliper-symptoms/
https://auto.howstuffworks.com/auto-parts/brakes/brake-types/power-brake.htm