**Hydraulic Brake System and Its Operation**
The hydraulic brake system works by converting the force applied to the brake pedal into hydraulic pressure, which is then used to generate braking torque. This mechanism is relatively simple, but the braking force produced is directly proportional to the force applied on the pedal. When the tire's grip on the road is sufficient, the vehicle’s braking force increases linearly with the driver's effort, creating what is known as the "brake pedal feel." This feature allows the driver to sense whether the braking system is functioning properly, enabling quick diagnosis of potential issues.
Common problems in hydraulic brake systems include brake failure or improper braking performance. Below are two typical issues: **brake failure** and **brake bite**.
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**1. Brake Failure**
**Symptoms**: When the vehicle is in motion, pressing the brake pedal does not result in immediate deceleration. The car takes longer to stop, and the braking distance increases significantly.
**Causes**:
1. Excessive free travel of the brake pedal.
2. Low brake fluid in the master cylinder, or a blocked compensation hole. The master cylinder cup, diaphragm, or other components may be aged, swollen, or deformed.
3. Worn piston or cylinder in the master cylinder, leading to oil leakage. A faulty return valve or broken outlet spring can also cause this issue.
4. Faulty brake cylinders with swollen or stuck pistons, or excessive wear between the piston and cylinder.
5. Worn brake shoes, incorrect brake gap, or reversed clearance.
6. A worn or warped brake drum, oil on the brake shoe surface, hardened friction material, or exposed rivets.
7. Air in the hydraulic system, or overheating causing vaporization of brake fluid, creating air resistance.
8. Damaged or clogged brake lines, loose connections, or aging hoses.
**Diagnosis and Troubleshooting**:
To diagnose brake failure, the “three-step brake test†can be used: light pedal, fast pedal, and even pedaling.
- **Step 1 – Light Pedal**: Gently press the pedal. If it feels firm at 2/3 of its stroke, the free travel is too high. If the pedal feels hard or unresponsive, there may be internal blockage or fluid degradation. If it feels soft, air or vaporized fluid may be present. If the pedal doesn’t return, the return valve might be clogged or damaged.
- **Step 2 – Fast Pedal**: Press the pedal quickly. If the brakes don't engage, check for improper installation of the quick-locking joint. If the pedal moves freely when pressed slowly but not when pressed quickly, there may be internal leaks or worn components.
- **Step 3 – Even Pedaling**: Press the pedal several times. If it stays at the bottom without resistance, check for low brake fluid, blocked vents, or damaged cups. If the pedal returns and braking improves, the issue may be related to pedal free travel or brake clearance.
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**2. Brake Bite**
**Symptoms**: The vehicle struggles to accelerate, and after some distance, the brake drums become hot. One or more wheels may feel as if they are continuously applying the brake.
**Causes**:
1. No free travel on the brake pedal.
2. Too little clearance between the brake drum and shoe, or a broken or weak return spring.
3. Contaminated or overly viscous brake fluid that prevents proper oil return.
4. Blocked bypass hole in the master cylinder, or swollen, deformed, or aged cups.
5. A weak or broken return spring in the master cylinder piston, or a stuck piston.
**Diagnosis and Troubleshooting**:
First, determine if the issue affects the entire vehicle or just one wheel.
- **If all wheels are affected**: Check the pedal free travel. Open the master cylinder reservoir and press the pedal step by step. If the fluid doesn’t return, clean or replace the brake fluid. If fluid is expelled when loosening the bleeder bolt, the system may have a blockage.
- **If only one wheel is affected**: Apply the brake, then loosen the bleeder bolt. If fluid is released, check for blockages in the line. If the brake shoe still doesn’t release, adjust the clearance. If everything checks out, inspect the piston, cup, or other components that may be preventing the shoe from returning.
By following these diagnostic steps, drivers and technicians can identify and resolve common issues in hydraulic brake systems efficiently.
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