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WorksheetsBrakes pgs. 91-132
Total questions: 30
Worksheet time: 15mins
Which symptom listed under brake service tips indicates the brakes are too responsive to small inputs?
Brake fade
Wheel drag
Brakes too sensitive
Spongy pedal
During wheel assembly installation, what is the correct initial step after cleaning and inflating the tires to recommended pressure?
Tighten lug nuts fully with a torque wrench
Place the wheel on the hub and install the lug nuts finger-tight
Lower the vehicle and finish tightening the lug nuts
Inspect wheel studs and lug nuts for condition
Which advantage is specifically noted for disc brakes over drum brakes?
Increased pulling and grabbing
Better fade resistance
Lower heat dissipation
No need for brake pads
Which components are identified as part of a disc brake system?
Rotor, hub, caliper assembly, brake pads, mounting bolts
Drum, shoes, wheel cylinder, backing plate
Master cylinder, vacuum booster, proportioning valve
Axle shaft, differential, driveshaft
What is the primary function of a disc brake caliper?
Ventilate the rotor to cool the brakes
Convert hydraulic pressure into mechanical force pushing pads against the rotor
Measure rotor runout during inspection
Secure the wheel to the hub
Which is a major part common to all disc brake calipers?
Backing plate
Wheel cylinder
Caliper body or housing with internal hydraulic passages
Brake shoe return springs
Why are disc brakes generally considered more effective than drum brakes under heavy use?
They trap heat inside the drum
They dissipate heat more quickly and can be ventilated to cool themselves
They use thicker pads that last longer
They operate only on the rear wheels
Which statement best distinguishes floating calipers from sliding calipers in disc brake systems?
Floating calipers use machined guides and bushings; sliding calipers use mounting bolts and bushings.
Floating calipers are rigidly mounted and do not move; sliding calipers have multiple pistons on one side.
Floating calipers use mounting bolts and bushings; sliding calipers operate on machined guides and bushings.
Floating calipers require brake return springs; sliding calipers use self deflection.
Compared to sliding calipers, fixed caliper disc brakes typically:
Provide inferior braking but cost less, found on economy vehicles.
Provide superior braking performance and are more expensive, typically found on performance or luxury vehicles.
Use brake return springs to release pads.
Have a single piston mounted on both sides of the caliper.
During visual inspection of a disc brake system, which action is specifically cautioned against?
Use proper lifting equipment and raise the vehicle.
Clean all disc brake components with a brake washer.
Do not breathe the dust that comes off the brakes or allow it to escape into the air.
Check the fluid level in the master cylinder.
What is the minimum acceptable thickness standard for a brake lining that is riveted to the backing plate to be considered usable?
Rivet heads more than 1/8 inch below lining surface
Rivet heads more than 1/16 inch below lining surface
Rivet heads exactly flush with lining surface
Rivet heads more than 1/64 inch below lining surface
Which statement correctly compares the two common types of disc brake pad wear indicators?
Mechanical indicators use embedded electrical connectors; electrical indicators use a metal strip that chirps.
Mechanical indicators use a metal strip that rubs the rotor to produce a chirping sound; electrical indicators use pad-embedded connectors that trigger a warning light when contacting the rotor.
Both types rely on pad-embedded sensors that ground to illuminate the instrument panel.
Electrical indicators produce an audible chirp; mechanical indicators illuminate a warning light.
Which step helps prevent brake fluid overflow when compressing caliper pistons during service?
Remove the caliper mounting bracket
Take off the master cylinder cover and remove a small amount of fluid from each chamber
Pump the brake pedal rapidly
Clamp the brake hose with pliers
When compressing pistons on a floating caliper, what tool and action are recommended to push the piston back into the bore?
Use a pry bar to force the caliper off the rotor
Use a pad spreader and turn the screw to press the outer pad against the rotor
Use a hammer to tap the piston inward
Use compressed air through the bleeder valve
Which safety caution is emphasized when using compressed air to blow out a caliper piston?
Always use gasoline to clean the caliper first
Keep your hands clear of the inside of the caliper and keep others out of the area
Stand directly in front of the piston to observe movement
Increase air pressure until the piston ejects forcefully
After cleaning internal caliper parts with approved brake solvent, which finding requires replacing the pistons?
Minimal dust on pads
Pitting, rusting, cracks, chipping, or scoring
Slight discoloration
Presence of new seals
During reassembly, what is the correct practice for installing seals and pistons into caliper bores?
Force pistons to the bottoms of the bores to seat them
Lubricate all parts with clean brake fluid and manually insert seals and pistons without excessive pressure
Use engine solvent for lubrication
Install seals dry and press pistons in with a clamp
Which component pair of a micrometer is made together and threaded into the sleeve, moving in or out when the thimble is rotated?
Frame and anvil
Ratchet and locknut
Spindle and thimble
Sleeve and frame
Pulsating pedal and brake fade are typically the result of problems in which rotor measurement areas?
Pad material hardness and rotor diameter
Parallelism (thickness variation) or lateral runout
Caliper slide lubrication and hose condition
Master cylinder fluid level and pedal linkage
Before making thickness variation checks on a rotor, what initial inspection should be performed?
Measure lateral runout with a dial indicator
Examine the rotor for grooves
Retighten wheel nuts to the hub
Check bearing adjustment
During rotor lateral runout measurement, how is runout determined from dial indicator readings?
Add the highest and lowest readings
Subtract the lowest reading from the highest reading
Average multiple readings around the rotor
Record the first reading after zeroing
Which statement best explains why a rotor below minimum thickness should not be reused?
It increases braking power by reducing mass
It has less metal to dissipate heat, leading to brake fade and potential overheating
It improves pad wear and reduces scoring
It prevents lateral runout during machining
In an off-car brake lathe scratch test, why should the scratches cover only about 1/3 of the rotor?
To reduce friction during the test
Because of runout that causes the bits to contact only part of the rotor
To prevent overheating the rotor
To mark the midpoint of the rotor’s friction surface
What is the recommended maximum depth for a regular pass when machining a rotor on an off-car lathe?
0.002 inch
0.004 inch
0.010 inch
0.020 inch
Before machining on-vehicle, what should be attached to compensate for hub and adapter runout?
A rotor silencer band
A dial indicator
A cross-feed lever
A torque wrench
During on-vehicle machining, what are acceptable cut depths for a standard pass and a finish pass, respectively?
0.020 inch and 0.010 inch
0.010 inch and 0.002 inch
0.004 inch and 0.001 inch
0.012 inch and 0.006 inch
Strategic scenario: You measure a rotor after machining and find one side is like new while the other is significantly worn, with thickness just above minimum on the thin side. What is the proper action?
Accept it because average thickness is above minimum
Proceed if lateral runout is within spec
Reject it because both sides must be of equal thickness and not below minimum on either side
Polish the rotor surface to balance thickness
Which step is part of the commonly recommended brake pad break-in/burnishing procedure?
Perform 5 to 8 moderate brake applications from 40 to 10 MPH
Accelerate rapidly from 10 to 60 MPH several times
Drive continuously without braking for 10 miles
Perform only one hard stop from 60 to 0 MPH
Which of the following brake symptoms can be caused by wheel bearing problems?
Pedal pulsation
Brake pull
Grabbing
All of the above
Tech A says that a brake pedal that does not return all the way causes the brake warning light on the instrument panel to stay on. Tech B says that a brake pedal that does not return causes the brake lights to stay on. Who is correct?
Tech A
Tech B
Both A and B
Neither A nor B
