The braking system is one of the most critical safety components in a vehicle. Any malfunction can lead to serious consequences if not addressed promptly. Below are common issues that may occur with the brake system and their corresponding repair procedures:
1. **Poor Braking or Complete Failure**
- A leak or blockage in the brake lines (such as at joints) can cause low brake fluid levels, reducing hydraulic pressure and resulting in ineffective braking. Regular inspection and maintenance of the brake lines, along with adding fluid when necessary, are essential.
- Air entering the brake system can cause vaporization of brake fluid, creating bubbles that reduce braking efficiency. During service, bleed the brake cylinder and refill with the correct amount of fluid.
- An improperly adjusted brake gap can lead to delayed response and reduced braking force. Adjust the gap using a flathead screwdriver through the adjustment hole, ensuring proper clearance by returning the ratchet 3–6 teeth.
- If the brake drum is out of round or the brake shoes are warped, contact between the drum and lining will be poor, leading to reduced friction. In such cases, the drum should be machined or replaced if necessary.
- Contaminated or wet brake linings can significantly lower the coefficient of friction. Clean them with gasoline and bake them with a torch to remove oil. If water is present, use repeated braking to dry them.
- Damage to the master cylinder or wheel cylinder can result in internal leakage and loss of pressure. These components should be inspected and repaired or replaced as needed.
2. **Brake Pulling to One Side**
- Uneven brake gap or contact area on either side can cause the vehicle to pull during braking. Re-adjust the front and rear brakes and ensure even contact.
- Differences in braking force between left and right wheels can result from uneven tire pressure, oil contamination, or leaks. Check and adjust tire pressure, clean the pads, and fix any leaks.
- Suspension issues, such as a deformed spring or misalignment, can also cause pulling. Inspect the suspension components and make necessary repairs.
- Uneven surface roughness on the brake drums or air in the brake line can cause the car to pull. Diagnose and address these issues accordingly.
- Uneven tire inflation can lead to different rolling radii, causing the vehicle to drift. Ensure both tires are inflated to the manufacturer’s specifications.
- Misaligned wheel geometry or uneven tire wear can also contribute to pulling. Adjust alignment or replace worn tires as needed.
3. **Brake Noise**
- A warped brake drum or excessive runout can cause noise during braking. Resurface or replace the drum if necessary.
- Smooth or contaminated brake linings can create noise due to gliding or foreign objects. Remove the drum, clean the surface, and sand the linings to improve contact.
- Worn or damaged brake linings can cause irregular contact and noise. Replace the linings and check for any deformation in the brake backing plate.
- Faulty wheel bearings can produce unusual noises under braking. Replace the bearing if damage is found.
4. **Brake Drag or Overheating**
- A small brake gap or insufficient pedal free play can cause the brake to remain engaged, leading to overheating. Adjust the gap according to specifications.
- If the brake pedal is not fully released, it can cause prolonged friction and heat. Ensure the pedal is properly adjusted.
- A faulty return spring can prevent the brake assembly from releasing properly, leading to overheating. Repair or replace the spring as needed.
5. **Parking Brake Failure**
- Corrosion, broken cables, or stretched springs in the parking brake system can cause the brake to fail. Inspect the cable, housing, and spring, and replace any damaged parts.
- Ensure the cable moves smoothly and the handle operates correctly. When applying the parking brake, a force of 196N should move the tooth plate 5–7 teeth. If more than 7 teeth are required, the gap may be too large or the cable stretched, and adjustments should be made.
Regular inspection and proper maintenance of the braking system are crucial for safe driving. Always follow the manufacturer's guidelines when performing repairs or adjustments.
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