Shop Manual : Class Text

by Chek-Chart Staff

• ISBN13: 9781579322809
• ISBN10: 1579322808
• Edition: 3rd
• Format: Hardcover
• Copyright: 2000-04-01
• Publisher: Chek-Chart Products

Table of Contents

Introduction	iv
How to Use this Book	v
PART ONE --- GENERAL BRAKE SERVICE OPERATIONS	1	(44)
Shop Practices and Special Tools, Cleaners, and Lubricants	2	(26)
Shop Practices	2	(2)
Tricks of the Trade	4	(1)
Cleaning Tools	5	(3)
Chemical Cleaners	8	(1)
Adjusting Tools	8	(1)
Special Wrenches	9	(2)
Tubing Tools	11	(1)
Assembly/Disassembly Tools	12	(5)
Measuring Tools	17	(5)
Cylinder and Caliper Refinishing Tools	22	(1)
Friction Component Refinishing Tools	23	(1)
Hydraulic Service Tools	24	(1)
Lubricants	25	(3)
Brake System Diagnosis	28	(17)
Talking to the Customer	28	(1)
Brake System Road Testing	29	(1)
Road Test Procedure	29	(4)
Brake Inspection	33	(1)
Brake System Diagnostic Charts	34	(11)
PART TWO --- BRAKE HYDRAULIC SYSTEM SERVICE	45	(56)
Fluid-Related Brake Service	46	(16)
Fluid Level Checking	46	(3)
Brake Bleeding	49	(1)
Master Cylinder Bench Bleeding	50	(3)
Master Cylinder On-Car Bleeding	53	(1)
Bleeding the Wheel Brakes	54	(5)
Bleeding the Teves ABS System	59	(1)
Fluid Changing	60	(1)
Recentering Pressure Differential Switches	60	(2)
Brake Line, Hydraulic Valve, and Electrical Component Service	62	(21)
Brake Line Inspection	62	(2)
Brake Hose Replacement	64	(2)
Brake Tubing Replacement	66	(1)
Brake Tubing Fabrication	67	(3)
Hydraulic Control Valve Service	70	(5)
Brake Electrical Component Tests	75	(1)
Stoplight Circuit Tests and Adjustments	76	(3)
Warning Light Circuit Tests	79	(1)
Failure Warning System Switch Tests	80	(3)
Pedal Assembly, Master Cylinder, and Wheel Cylinder Service	83	(18)
Brake Pedal Assembly Service	83	(2)
Hydraulic Cylinder Inspection and Testing	85	(1)
Master Cylinder Inspection	85	(1)
Master Cylinder Testing	86	(2)
Wheel Cylinder Inspection	88	(1)
Master Cylinder Replacement	89	(1)
Wheel Cylinder Replacement	90	(1)
Hydraulic Cylinder Overhaul	91	(3)
Master and Wheel Cylinder Overhaul Procedures	94	(1)
Ford Cast-Iron Dual Master Cylinder Overhaul	95	(2)
GM Aluminum QTU Master Cylinder Overhaul	97	(2)
Two-Piston Wheel Cylinder Overhaul	99	(2)
PART THREE --- WHEEL FRICTION ASSEMBLY SERVICE	101	(104)
Drum Brake Service	102	(29)
Brake Drum Removal	102	(4)
Drum Brake Inspection	106	(3)
Brake Adjusting	109	(1)
Brake Adjusting Procedure	110	(1)
Specific Brake Adjusters	111	(3)
Brake Shoe Replacement	114	(4)
Initial Brake Adjustment	118	(2)
Brake Shoe Burnish-in	120	(1)
Shoe Replacement Procedures	121	(1)
Chrysler Leading-Trailing Brake with Manual Adjuster	122	(2)
Chrysler Dual-Servo Brake with Cable Type Starwheel Automatic Adjuster	124	(3)
GM Dual-Servo Brake with Lever-Type Starwheel Automatic Adjuster	127	(2)
Ford Leading-Trailing Brake with Strut-Quadrant Automatic Adjuster	129	(2)
Disc Brake Service	131	(45)
Brake Pad Inspection	131	(2)
Brake Pad Replacement	133	(3)
Brake Pad Burnish-in	136	(1)
Brake Caliper External Inspection	136	(2)
Brake Caliper Overhaul	138	(1)
Brake Caliper Piston Removal	139	(4)
Brake Caliper Internal Inspection	143	(1)
Brake Caliper Honing	144	(2)
Brake Caliper Assembly	146	(3)
Pad Replacement and Caliper Overhaul Procedures	149	(1)
GM Single-Piston Floating Caliper Service	150	(5)
Chrysler Single-Piston Sliding Caliper Service	155	(3)
GM Four-Piston Fixed Caliper Service	158	(4)
Ford Single-Piston Rear Caliper Service	162	(7)
GM Single-Piston Rear Caliper Service	169	(7)
Brake Drum, Rotor, and Shoe Machining	176	(29)
Drum and Rotor Service	176	(1)
Visual Drum and Rotor Inspection	177	(1)
Brake Drum Measurement	178	(2)
Brake Rotor Measurement	180	(3)
Drum Replacement	183	(1)
Drum and Rotor Refinishing	183	(1)
Brake Lathe Operation	184	(5)
Turning a Brake Drum	189	(5)
Grinding a Brake Drum	194	(1)
Rotor Turning Procedures	195	(1)
Turning a Brake Rotor off the Car	195	(4)
Turning a Brake Rotor on the Car	199	(2)
Resurfacing a Brake Rotor	201	(1)
Arc Grinding a Brake Shoe	201	(4)
PART FOUR --- BRAKE SUBSYSTEM TESTING AND SERVICE	205	(112)
Parking Brake Service	206	(11)
Parking Brake Testing	206	(3)
Parking Brake Adjustment	209	(1)
Parking Brake Shoe Adjustment	209	(1)
Parking Brake Cable Adjustment	210	(2)
Parking Brake Cable Replacement	212	(3)
Parking Brake Shoe and Pad Service	215	(1)
Vacuum Release Parking Brake Service	215	(2)
Power Brake Service	217	(15)
Vacuum Booster Testing	217	(2)
Vacuum Booster Output Pushrod Adjustment	219	(2)
Vacuum Booster Replacement	221	(1)
Hydro-Boost Testing	222	(4)
Hydro-Boost Replacement	226	(1)
Hydro-Boost Bleeding	226	(1)
Powermaster Testing	227	(3)
Powermaster Replacement	230	(1)
Powermaster Fill and Bleed	230	(2)
Antilock Brake Basics	232	(13)
Service Basics	232	(6)
Onboard Diagnostics	238	(2)
ABS Performance Checks, Precautions, and Procedures	240	(4)
General Bleeding Procedures	244	(1)
ABS Diagnostic and Service Procedures	245	(46)
Bendix ABS Systems	245	(8)
Bosch ABS Systems	253	(9)
Delco ABS Systems	262	(5)
Kelsey-Hayes ABS Systems	267	(9)
Sumitomo ABS Systems	276	(4)
Teves ABS Systems	280	(7)
Toyota ABS	287	(4)
Bearing, Tire, Wheel, and Chassis Service	291	(26)
Types of Wheel Bearings	291	(2)
Wheel Bearing Diagnosis	293	(3)
Basic Wheel Bearing Service	296	(3)
Adjustable Dual-Wheel Bearing Service	299	(3)
Sealed Wheel Bearing Replacement	302	(5)
Solid Axle Wheel Bearing Service	307	(3)
Tire and Wheel Service	310	(2)
Tire and Wheel Runout	312	(3)
Chassis Service	315	(2)
Index	317