The brake system is one of the fundamental components of vehicle safety. Periodic inspection of this system plays a critical role not only in ensuring safe driving but also in extending the lifespan of its components. However, mistakes made during brake system maintenance can compromise its effectiveness and lead to serious consequences.
In this article, we discuss the most common mistakes in brake system maintenance in technical detail and highlight the key points to ensure proper maintenance procedures.
Neglecting Brake Pads
Brake pads are wear components that transfer braking force to discs or drums. Therefore, they must be checked periodically and replaced when necessary. A common mistake is delaying pad replacement or only responding when unusual noise is heard.
Worn or hardened pads can cause deformation on the surface of brake discs or drums, often felt as vibration in the front wheels when the brake pedal is pressed. While disc brake systems do not require adjustment, failing to adjust drum brakes after pad replacement is another frequent issue.
Key Points to Consider for Brake Pads
- Contact surfaces should never be lubricated.
- Pads should be replaced if the groove depth is below 1 mm.
- Hardened pads may become glazed, reducing braking performance.
Skipping Disc and Drum Inspection
Brake maintenance must also include a thorough inspection of brake discs and drums. Overheating can lead to thinning, cracking, or surface warping. These issues may cause inconsistent brake responses.
One commonly misunderstood practice is reusing worn discs by turning them on a lathe. This reduces disc thickness and negatively affects braking distance and safety.
Ignoring Handbrake Adjustment
Handbrake mechanisms vary between disc and drum systems. In both, improper handbrake adjustment increases the risk of the vehicle rolling when parked. Issues such as a broken or loose handbrake cable are often overlooked, creating serious safety hazards.
To ensure proper handbrake operation:
- Handbrake cables should be inspected regularly.
- Tension and slack should be adjusted according to manufacturer specifications.
- If an automatic adjuster is present, adjustment should be completed by pulling the lever several times.
Neglecting Brake Fluid Inspection
Brake fluid, the most critical fluid in the braking system, absorbs moisture over time, lowering its boiling point. This results in delayed braking response, increased stopping distance, and in some cases, complete brake failure. A common mistake is simply topping off the fluid when low—this can introduce air into the system and degrade brake performance.
Brake fluid should be replaced every 2 years or when its moisture level exceeds 3%. This should be measured with a specialized tester pen.
During fluid replacement:
- Old fluid must be fully drained.
- Air must be purged from the system and fluid filled to the maximum level.
- The reservoir cap must be tightly closed to prevent air contact.
Errors in Caliper Maintenance
Proper caliper operation is vital for balanced and effective braking in disc systems. Sticking pistons, contamination, or water intrusion into rubber seals can impair function. A common mistake is skipping caliper inspection during pad replacement.
If pistons are hard to retract or braking is inconsistent, caliper servicing may be required. Failing to tighten caliper bolts to the correct torque, or leaving them loose, poses a serious safety risk.
Overlooking Brake Booster (Brake Servo) Failures
In modern vehicles, the brake booster enhances braking force using engine vacuum. A torn diaphragm or loose vacuum hose in the booster can cause pedal stiffness and increased stopping distance.
Some superficial inspections may fail to detect these issues. Therefore, if you notice:
- Sudden stiffness in the brake pedal,
- A decline in braking performance,
- A hard pedal when pressing the brake while the engine is off,
then the brake booster should be checked.
Failing to Visually Inspect Pressure Regulator and Hoses
Cracked, worn, or loose brake hoses and fittings can lead to fluid leaks. As these components are exposed to external impacts, they should be visually inspected periodically.
A common mistake is only checking for oil leaks. However, issues such as:
- Swelling,
- Cracking,
- Loose connections,
- Corrosion on metal fittings,
are all hazardous and must be addressed.
Not Measuring Pedal Height and Stroke Travel
Pedal height, stroke travel, and free play must be measured against the vehicle's specifications. Insufficient pedal height can delay braking, while excessive stroke may reduce braking force.
Stiff pedals, the pedal sticking at the bottom, or varying response after repeated presses are signs of a system fault.
Only Visually Inspecting the ABS System
ABS systems only activate during wheel lock conditions, making faults difficult to detect in normal driving. A common mistake is relying solely on visual inspection of the ABS system.
Proper ABS testing requires a diagnostic tool to check the electronic control unit, sensors, and modulator. While warning lights on the dashboard often indicate faults, these may not always function correctly, so diagnostic devices are essential.
Conclusion
Brake system maintenance is a complex process that goes far beyond pad replacement. Even small mistakes during maintenance can directly threaten driving safety. At Yavuzsan, we encourage all vehicle owners to take brake system maintenance seriously and have their systems serviced by qualified professionals, on time and with care.
Neglect has no place in brake safety. With accurate knowledge and proper practices, you can extend your vehicle’s lifespan and ensure your safety on the road.
