SOUTHWESTERN MICHIGAN COLLEGE
School of Technology
Dowagiac, Michigan
COURSE SYLLABUS
Fall Session, 2004
COURSE TITLE: Brakes & Chassis COURSE NO.: AUTO115
SECTION NO.: 1201
CREDITS/CONTACTS: Credit Hours: 4
Lecture hours/weekly: 2
Laboratory hours/weekly: 5
A-T hours/week:
INSTRUCTOR: Mr. Randy Jacobsen
Office Hours: By appointment
Phone Number: 269-782-1266
Email:
PREREQUISITE: None
COURSE DESCRIPTION: Covers the diagnosis, inspection and repair of the braking system. Discussion and testing of the Anti-Lock Brake System is also covered.
CORE CURRICULUM: Non-applicable
MACRAO/DISTIBUTION REQUIRMENTS: Non-applicable
TEXTBOOK REQUIRED: Automotive Brake Systems, Third Edition. James D Halderman- Chase D Mitchell, Jr. Pearson Prentice Hall, Inc. Upper Saddle River, New Jersey.
OPTIONAL: Non-applicable
ADDITIONAL RESOURCES: Workbook to accompany textbook.
Voucher - available at the SMC Bookstore (covers the cost of the State Exam, Resource binder, as well as other consumable materials).
NOTICE: Information in this syllabus, was to the best knowledge of the instructor, considered
correct and complete when distributed for use at the beginning of the semester. The instructor,
however, reserves the right, acting within the policies and procedures of Southwestern Michigan
College, to make changes in course content or instructional techniques.
HONESTY POLICY
Cheating or plagiarizing will absolutely not be tolerated at Southwestern Michigan College. Any
student found cheating or plagiarizing material in any manner may be assigned a failing
semester/session grade in this course. A second such incident while at SMC could result in
suspension or expulsion from the institution. A student found in violation of this section of the
syllabus will not be allowed to drop this course. Additional detail regarding cheating and/or
plagiarism may be found elsewhere in this syllabus.
METHOD OF INSTRUCTION: AUTO115 will use a combination of lecture, discussion,
audio visual, selected textbook readings, handouts, and
laboratory projects providing practical experiences in working
with all aspects of the common brake systems in the automotive
industry.
Problem solving and trouble shooting brakes and related systems
will also be a part of the scope of this class. Group projects and
cooperative group experiences will be used in the classroom as
well as the laboratory.
Because of the industry standards in the automotive field, testing
methods that simulate state and ASE tests will be regularly used.
However, a variety of assessment methods will be used to
indicate and facilitate student learning. These include written
exams, projects and lab performance, oral participation in class,
as well as attendance to class and lab.
Student grades will be figured on a percentage basis and will be
weighted as follows:
Quizzes / Daily Assignments 20%
Tests 20%
Laboratory Work 40%
Final Exam 20%
100%
GRADING SCALE: The following grading scale will be in effect for this course:
A = 94 - 100%
A- = 90 - 93 %
B+ = 87 - 89%
B = 84 - 86%
B- = 80 - 83%
C+ = 77 - 79%
C = 74 - 76%
C- = 70 - 73%
D+ = 67 - 69%
D = 64 - 66%
D- = 60 - 63%
F = 0 - 59%
ATTENDANCE POLICY: Attendance will be recorded for each class period as per college policy. Due to the cooperative and group leaning methods, as well as the extensive use of the laboratory used in this class, regular attendance is crucial to successful completion of this course.
TESTING POLICY: Quizzes will be given on an unscheduled basis. Tests will be administered according to the Assignment Schedule, variations to the schedule will be discussed in class.
ABSENCE FROM A TEST OR QUIZ: You are expected to be present in class to take all tests and quizzes. Students absent from a test or quiz need to make arrangements with the instructor to make them up within a week of when the test or quiz was originally given. Failure to make up a quiz or test within this time frame may result in a grade of “zero” for that particular exercise. However, the final exam must be taken no later than at the regularly scheduled time.
NOTE: Students will be required to take the Michigan State Certification Exam for brakes at the end of the semester. The test will be available at SMC and the cost of $6.00 is included in the voucher that is to be purchased at the bookstore before the beginning of the course. The results of this test will be made available to the instructor and/or institution to be used for program assessment only. Students who pass will be eligible for certification by the State of Michigan.
OTHER COURSE Shop Policies: All shop policies must be followed using safe
EXPECTATIONS work practice rules. These include, but are not limited to:
1. All vehicles that enter the shop must have a current repair order.
2. Any vehicle that is run in the shop must have an exhaust system in functional condition and it must be hooked to the shop’s ventilation system.
3. Students must wear appropriate eye protection in the shop at all times.
4. Steel toed shoes are recommended, however, a minimum of closed toed shoes are required.
5. Students with an Employer Sponsor are encouraged to wear the uniform of their sponsor.
6. Neat and safe dress and appearance is required at all times. No frayed or torn clothing is permitted.
7. Shop organization and cleanliness is the responsibility of all who enter the auto lab. Each individual who enters the auto lab is to bear responsibility for keeping it clean, organized, and safe.
NOTE: Profanity, ethnic or gender specific comments or jokes have no place in the shop, classroom, or workplace. Lack of respect for other students, personal or school property is taken seriously and will be dealt with in an appropriate manner.
COURSE OBJECTIVES: Upon completion of this course, the student will be able to demonstrate a basic knowledge of the subject matter as evidenced in the associated laboratory projects assigned. The student should be prepared, upon course completion, to perform routine service and diagnosis on the types of assemblies covered in the lab and class topics.
SPECIFICALLY: Students will be able to correctly perform the following tasks in an industry-accepted quantity of time:
Skill Objectives:
1. Recondition wheel cylinders
2. Recondition brake calipers
3. Resurface brake drums
4. Resurface brake rotors
5. Clean, inspect, and repack wheel bearings and grease seals
6. Inspect, remove, and recondition master cylinders
7. Remove and replace all components of automobile brake systems
8. Double flare steel brake lines
9. Bleed hydraulic brake systems
10. Identify, test, and replace components of anti-lock brake systems
Knowledge Objectives:
1. Describe and practice correct procedures for handling the hazardous materials involved in brake service
2. Describe the operation of the braking system
3. Describe the operation of the anti-lock brake system
4. Describe the testing and inspection procedures to accurately determine brake system needs
In addition, students will be able to perform the tasks as listed in the “NATEF Task List” that follows.
NATEF TASK CORRELATION
What follows is a list of tasks supplied by the National Association of Automotive Service Excellence (ASE). This is part of the NATEF certification of SMC as a training facility. You can expect that these items will be performed in the lab, discussed in class, and /or covered in the text.
Section V: Brakes
A. Hydraulic System Diagnosis and Repair
1. Measure and adjust pedal pushrod length and pedal height
2. Check master cylinder for internal and external leaks and proper operation; determine needed repairs
3. Remove, bench bleed, and replace master cylinder
4. Diagnose poor stopping, pulling or dragging caused by problems in the hydraulic system; determine needed repairs
5. Inspect brake lines and fittings for leaks, dents, kinks, rust, cracks, or wear; tighten loose fittings and supports
6. Inspect flexible brake hoses for leaks, kinks, cracks, bulging or wear; tighten loose fittings and supports
7. Fabricate and install brake lines (double flare and ISO types); replace hoses, fittings, and supports as needed
8. Select, handle, store, and install brake fluids to proper level
9. Inspect, test, and replace metering (hold-off), proportioning (balance), pressure differential, and combination valves
10. Inspect, test, replace, and adjust height (load) sensing proportioning valve
11. Inspect, test, replace components of brake warning light system
12. Bleed (manual, pressure, vacuum or surge) brake system; flush hydraulic system
B. Drum Brake Diagnosis and Repair
1. Diagnose poor stopping, noise, pulling, grabbing, dragging or pedal pulsation
problems; determine needed repairs
2. Remove, clean (using proper safety procedures), inspect, and measure brake
drums; service or replace as needed
3. Mount brake drum on lathe; machine braking surface
4. Remove, clean, and inspect brake shoes, springs, pins, clips, levers, adjusters/self-adjusters, other related brake hardware, and backing support plates; lubricate and reassemble
5. Remove, and reinstall wheel cylinders
6. Pre-adjust brake shoes and parking brake before installing brake drums or drum/hub assemblies and wheel bearings
7. Reinstall wheel, torque lug nuts, and make final checks and adjustments
C. Disc Brake Diagnosis and Repair
1. Diagnose poor stopping, noise, pulling, grabbing, dragging or pedal pulsation
caused problems; determine needed repairs
2. Remove caliper assembly from mountings; clean and inspect for leaks and
damage to caliper housing
3. Clean and inspect caliper mounting and slides for wear and damage
4. Remove, clean, and inspect pads and retaining hardware; determine needed service
5. Disassemble and clean caliper assembly; inspect parts for wear, rust, scoring, and damage; replace seal, boot, and damaged or worn parts
6. Reassemble, lubricate, and reinstall caliper, pads, and related hardware
7. Clean, inspect, and measure rotor with a dial indicator and a micrometer; follow manufacturer’s recommendations in determining need to machine or replace
8. Refinish rotor according to manufacturer’s recommendations
9. Adjust calipers with integrated parking brake system
10. Fill master cylinder with recommended fluid and seat pads; inspect caliper for leaks
11. Reinstall wheel, torque lug nuts, and make final checks and adjustments
12. Remove and replace brake rotors.
D. Power Assist Units Diagnosis and Repair
1. Test pedal free travel with and without engine running; check power assist
operation
2. Check vacuum supply (manifold or auxiliary pump) to vacuum-type power
booster
3. Inspect the vacuum-type power booster unit for vacuum leaks; inspect the check
valve for proper operation; repair or replace parts as needed
E. Miscellaneous (Wheel Bearings, Parking Brakes, Electrical, Etc.)
Diagnosis and Repair
1. Diagnose wheel bearing noises, wheel shimmy, and vibration problems;
determine needed repairs
2. Remove, clean, inspect, repack, and reinstall wheel bearings and replace seals;
reinstall hub and adjust wheel bearings
3. Check parking brake cables and components for wear, rusting, binding, and
corrosion; clean lubricate, and replace as needed
4. Check parking brake operation; adjust as needed
5. Check operation of parking brake indicator light system
6. Check operation of brake stop light system; adjust and service as needed
7. Replace wheel bearing and race
F. Anti-lock Brake System
1. Inspect, test, and service anti-lock brake system (ABS) hydraulic, electrical, and
mechanical components
2. Diagnose poor stopping, wheel lock-up, abnormal pedal feel or pulsation, and
noise problems caused by the anti-lock brake system (ABS); determine needed
repairs
3. Observe anti-lock brake system (ABS) warning light(s) at startup; determine if
further diagnosis is needed
4. Diagnose anti-lock brake system (ABS) electronic control(s) and components
using self-diagnosis and /or recommended test equipment; determine needed
repairs
5. Depressurize high pressure components of the anti-lock brake system (ABS)
following manufacturer's recommended safety procedures
6. Fill the anti-lock brake system (ABS) master cylinder with recommended fluid
following manufacturer's procedures
7. Perform a fluid pressure (hydraulic boost) diagnosis on the high pressure anti-
lock brake system (ABS); determine needed repairs
8. Remove and install anti-lock brake system (ABS) electrical/electronic/hydraulic
components following manufacturer's procedures and specifications
9. Service, test, and adjust anti-lock brake system (ABS) speed sensors following
manufacturer's recommended procedures
10. Diagnose anti-lock brake system (ABS) braking problems caused by vehicle
modifications (tire size, curb height, final drive ratio, etc)
The following tools are REQUIRED for all students:
Basic Tool Set
A toolbox capable of holding and organizing the following tools. Lower cabinet (cart) strongly suggested, as carts will be unavailable.
3/8 drive deep six point socket set, US: 3/8, 7/16, ½, 9/16, 5/8, 11/16, ¾, 13/16, 7/8
3/8 drive deep or shallow six point metric socket set: 8,9,10,11,12, 13, 14, 15, 17, 18, 19, mm
3/8 drive spark plug sockets, 5/8 and 13/16 (best to get the new deep design)
¼ drive socket set, US: ¼, 5/16, 3/8, 7/16, ½
¼ drive socket set, metric: 5, 5.5, 6, 7, 8, 9, 10, 11, 12, mm
Combination wrench set, US: ¼ to 7/8 by 1/16
Combination wrench set, metric: 7 to 21 mm
Screwdriver set: Standard, Phillips, and PosiDrive
Pliers: Slip joint
Pliers: Needle nose (recommend long neck with bent nose)
Pliers: Diagonal cutter
Pliers: 9” channel lock type
Pliers: 6” and/or 10” Locking (vice grip type)
Hammers: ball peen: 8 oz and 20 oz
Hammer: plastic tip or dead blow
Pry bar: 16”
Brass drift
Tire Gauge, 0 – 50 psi
HEI Spark Tester
Ramp type Spark Plug Gap Gauge
Tire Valve Core Remover Tool
Brake Spring hold down tool
Brake adjusting spoon
Brake return spring installer/remover
Allen sockets, 3/8” x 3/8” and 8mm x 3/8”
Torx socket, T40 and T50 x 3/8”
Spark plug boot removing pliers
Pocket Thermometer (analog or digital)
Non-powered test light
Tape measure, 25 foot
Recommended but optional:
Self powered test light Punch and Chisel set
Small flashlight Ext & int snap ring plier set
Feeler gauge set Wire stripper/crimper pliers
Set of Torx bits: ¼ Drive T8, T10, T15, T20, T25, Magnetic pick-up tool
and 3/8 drive T25, T27, T30, T40, T45, T50, T55
AUTO115
Brakes and Chassis