Part of Unit: Brake System Fundamentals
Lesson Plan Overview / Details
In this lesson, students will conduct a mechanical and hydraulic inspection of the disc and drum brake.
California Career and Technical Education Standards
- T.C.C1.1 Know and understand common environmental conservation practices and their applic...
- T.C.C1.5 Use appropriate personal protective equipment and safety practices.
- T.C.C3.3 Understand the basic principles of pneumatic and hydraulic power and their appli...
- T.C.C8.1 Understand how to maintain, diagnose, service, and repair hydraulic and power as...
- T.FS.11.0 Demonstration and Application
California Academic Content Standards (Reinforced)
Sudents will be able to:
- Identify the major parts of an automotive disc brake system, including the function of the master cylinder in the system.
- Demonstrate the ability to inspect and diagnose each component and explain what determines the need for replacement.
- Use all personal protective equipment that is appropriate for the task, as well as following safe work practices while using tools and chemicals.
- Follow all state, local and federal regulations pertaining to the disposal of hazardous waste.
- Estimate - time will vary
- 2 Hours
Activities in this Lesson
- Instructor prep - Other
Before the presentation, the instructor will need to have enough disc brake-equipped vehicles in the shop for the activity.
During the activity four students will be on a vehicle, two on a side. The instructor will save a lot of time if the vehicles are already lifted and supported by safety stands. The vehicles should also have rotors that have been freshly machined, since machining a rotor is covered in another lesson and there is no time in this lesson to do it.
The instructor will also need to make sure that there are enough brake service tools available for each work group so that they are not having to pass tools from one car to another. Having a shortage of tools will greatly diminish the effectiveness of this lesson, as will having students moving from one vehicle to another.
The instructor will also want to have each of the various brake components available (pads, rotors, calipers, etc.) so that they can hold them up and describe function and inspection.
- Donuts and Coffee - Hooks / Set
I start the lesson by having a big pink donut box in front of the class. As the class is seated, I begin to enjoy a donut and coffee and tell them about the benefits of BREAKS during a workday and that I would like to SHARE my involvement with BRAKES with them. This naturally gets them thinking that they will be enjoying a donut. I then turn around and present a handfull of brake pads and brake shoes.
(The instructor can get whatever they would like for the Hook; however, make sure that it is something that your students would like. A triple soy tofu eggbeater shake probably won't work.)
- Introduction to Brake System Hydraulics - Lab / Shop
Students are split into teams of four. Each team is given a vehicle and a set of tools and I place two students on each side of the vehicle.
The instructor begins the lesson by describing the master cylinder and its function in the brake system. The instructor should also cover how to diagnose a defective master cylinder. (At this point I don't spend much time on the brake booster other than quickly explaining its basic function because my goal in this lesson is to have the students become familiar with the components at the wheel assemblies.)
The instructor then has the students follow the routing of the brake lines and hoses to the wheel assemblies. During the process inspection of each component should be covered.
- Introduction to Disc Brakes - Lab / Shop
The instructor now takes the opportunity to name each of the components in the disc brake system, covering function of the brake calipers (floating and fixed), brake pads, caliper brackets, etc. as well as inspection.
After the students have been instructed on each of the components, the instructor walks the students through the disassembly of the disc brake assembly. After the groups have the wheel assemblies apart, they should inspect them and be instructed on the proper way of cleaning, taking into account the required safety precautions. The students should also be shown how to measure and inspect a rotor to determine if machining can be performed or replacement is necessary.
- Installation of Disc Brake Components - Lab / Shop
At this point the students are walked through the installation of the disc brake components. The instructor will need to check each group's progress to ensure that the components are being reassembled correctly. After assembly, the instructor will need to inspect each wheel assembly. At this time the instructor should have the students verbally demonstrate their knowledge of the materials covered. The other groups can particapate in this process to help reinforce the information that had been previously covered by the instructor.
- R&R Disc Brakes without help from Instructor - Demo / Modeling
Students model what they have learned and complete a disc brake job including cleaning and inspection of all components. The instructor will need to navigate around the class to assess the level of mastery of the students. After this task is completed, each group must put their tools away and clean up any mess that they have created during the lesson.
- Final Assessment - Assessment
During the activity the instructor will need to moniter the level of understanding by asking questions of the students as well as inspecting the quality. After the completion of the lesson, the instructor can inspect the repairs made by the students.
No resources are included, yet.
- Donuts/ Coffee for hook.
- Enough vehicles in the shop for no more than 4 students per car.
- Assortment of brake pads, calipers, caliper mounting brackets, rotors, and caliper retainers (bolts, pins).
- 3/8 drive socket sets, combination wrench sets, wire, lug nut socket sets, torque wrench, pliers, and side cutters for each group.
- Assortment of any special brake tools needed.
- Brake parts washer or brake cleaner.
- Brake lubricant.
- Disc brake micrometer.