Purpose
This procedure guides mechanics and inspectors in evaluating and maintaining critical brake system components including disc, drum, hydraulic, and air brake systems. Adherence to these steps ensures vehicle safety and FMCSA compliance.
Brake Maintenance Steps
Hydraulic System
- Inspect fluid level, clarity, and test for moisture contamination
- Check master cylinder, lines, and booster for leaks or damage
- Flush and bleed hydraulic system every 2 years or 30,000 miles
Disc Brakes
- Measure brake pad and rotor thickness
- Check caliper hardware, lubrication, and movement
- Replace pads and resurface/replace rotors if wear limits are exceeded
Drum Brakes
- Inspect shoe linings, hardware, and drum surface
- Verify wheel cylinder operation and absence of leaks
- Adjust shoes and verify return spring condition
Air Brakes (If Equipped)
- Drain air tanks, test air governor, and inspect valves
- Check compressor mounting and service air dryer
- Perform leak-down and application timing tests
Parking/Emergency Brake
- Test holding ability on incline
- Check cable condition and spring brake actuation
- Verify warning light function and adjusters
Brake Controls
- Inspect ABS modules, wheel sensors, and control units
- Test traction and stability systems
- Evaluate pedal free play, position, and brake light switch
Functional Testing
- Conduct brake pedal pressure and fade tests
- Perform ABS activation check and stopping distance test
- Evaluate brake noise, tracking, and pull during deceleration
Documentation
- Record component conditions, wear levels, and adjustments made
- Include test results and technician signatures
- Maintain records per FMCSA and fleet policies