How to use the brake cylinder repair kit

2024 Author: Erin Ralphs | [email protected]. Last modified: 2024-02-19 11:42

At the heart of every brake system are brake cylinders. They have a simple device. But in order to carry out repairs, you need to know their design, as well as the symptoms of failure. Repair involves the installation of new sealing elements, for which a brake cylinder repair kit is made. This is what we will talk about in our today's article.

Features of the braking system in a car

The working fluid has a low compression ratio due to its composition. It needs a very high temperature to boil. Therefore, it is used. Modern brakes are usually of the dual circuit type. The fluid moves along the contours and acts on the actuators, due to which the pads are compressed.

In vehicles with front wheel drive, the brakes for the front right and rear left wheels are serviced by the first circuit. The second is responsible for the front left and right rear. Designsystems in rear-wheel drive vehicles are slightly different. Here, the first circuit provides braking for the front wheels, and the second - for the rear.

Each of the two circuits in the brake system is separated by separate chambers located in the master cylinder or in the vacuum booster. This allows for the possibility of partial braking in case of failure of one of them. The described design is quite reliable, but sometimes it can fail. Therefore, to eliminate the breakdown, use a repair kit for a working brake cylinder or master cylinder (GTZ). It allows you to return the performance of important technical elements.

Brake cylinder device

The GTZ function is to transfer force from the pedal and convert it into pressure on the fluid, which will then put pressure on the brake mechanisms. The master cylinder is distributive. It is a housing, inside of which there are pushers and pistons.

There is a tank outside. It contains liquid. To increase the effectiveness of the brakes and reduce the required effort when pressing the pedal, modern cars also have a vacuum booster in the design. It is installed along with the GTZ. The latter is located directly above the cover of the vacuum booster. The tank with the GTZ has holes - compensation and bypass.

The device also has connecting tubes. They connect the tank with the liquid and the cylinder. Return springs ensure the movement of the piston to its original position. Cuffs serve as an obstaclefluid leaks. The system is also equipped with differential pressure sensors. In the event of a malfunction, they inform the driver of the car about breakdowns in the circuit.

The main elements of the GTZ are pistons. They are installed next to each other. The vacuum booster rod presses on one of them, while the second piston can move freely. The system is protected from leakage of the working fluid due to rubber cuffs. These elements have to be replaced periodically - for this, a brake cylinder repair kit is used.

Operation principle

When pressure is applied to the pedal, the VUT rod acts on the piston. It will block the compensation hole in the process of movement. This will lead to an increase in pressure in the first brake circuit. Then the pressure will increase in the other circuit.

The maximum amount of pressure will ensure the operation of the brake mechanisms. When the brakes are no longer needed, the pistons will return to their original position under the action of the return spring, and the pressure will again become close to atmospheric.

Typical malfunctions and symptoms

When the pads are worn out excessively or if the brake fluid leaks from the system, its level decreases, a diagnosis should be made. It is not recommended to operate the car until the malfunction is corrected. It is necessary to examine all elements of the system. Defective parts are replaced, and the main consumables are contained in the brake cylinder repair kit.

Depressurization, soft pedal, inefficient braking

The performance of a system may be reduced if it loses itstightness. The pedal becomes soft due to incomplete pumping or getting into the air circuits. These signs can also be observed if the main cylinder has failed, if the worker has jammed or overheated, or the liquid has boiled in it.

If the pedal is too hard, faults should be sought in the vacuum booster, hose or VUT control valve. If problems occur with the rear brakes, then the repair kit for the rear brake cylinder will come to the rescue.

Large pedal travel

This happens when the drum mechanisms are not properly adjusted. It can also happen with airing or worn pads. This malfunction is very dangerous, because in the right situation, braking will not be effective. This leads to emergencies.

If the brake pedal falls to the floor, the failure should be sought in the cylinders. Perhaps the working or main element is too worn out, or the system has been depressurized. To fix the problem, you need to replace the seal, and the brake cylinder repair kit will help with this.

Gripping

This indicates excessive pad wear. To fix this problem, just replace the pads or disc. Whistling speaks of low-quality friction elements. A repair kit is not needed in this case.

Pedal sticks and sticks

The reason for this malfunction is that the compensation hole in the GTZ housing is clogged or blocked.

If the pedal sticks, this indicates the wedging of the pistons in the GTZ due to dirt getting into the cylinder. It may also indicate the presence of excess moisture in the working fluid - it is hygroscopic. With dust, small solid particles can also enter the circuits of the system. That is why it is recommended to change the fluid in the system regularly.

Pedal does not return after pressing

There are several reasons for this malfunction. So, the return springs on the GTZ pistons may fail. Various breakdowns in the pedal drive are also possible.

Brake fluid on VUT case

Liquid or traces of it appear at the point where the VUT is connected to the brake cylinder. The reasons are related to the failure of the low pressure collar cuff in the master brake cylinder. It needs to be replaced. This element can be taken from the repair kit. It costs less than a new assembly.

What is included in the GTZ kit

So, the repair kit for the main brake cylinder of VAZ and other cars contains everything you need to restore the nodes. The complete set depends on the cost, the manufacturer, and also on the type of work for which this or that set is intended.

Consider what the brake cylinder repair kit for the VAZ-2110 contains. It contains:

1. Protective cap for GTZ.
2. Seals for head on piston.
3. Cuff for GTZ.
4. Cap for bleeder hose from clutch release cylinder.
5. Two pistons and return springs for them.
6. O-rings, seats.
7. Holders for springs.
8. Holder screws.

The kit may be incomplete, in which there are only GTZ cuffs and complete, where all the listed parts are present. Experts recommend that if you need to replace the brake cylinder repair kit, purchase the latest type.

Diagnosis

The first step is to carry out diagnostic procedures. So, they check the cylinder for smudges and cracks, as well as the sealing elements for tightness. Additionally, they look at the condition of the cylinder mirror - it should not have shells, as well as other damage. Geometric changes of the mirror are also not allowed. Then check the clearances between the cylinder and the pistons.

If there are any changes in the operation of the brake system, then the brake cylinder repair kit will help to repair it. True, with its help only minor malfunctions can be eliminated.

Restoring the performance of the cylinders

First of all, remove the negative terminal from the battery and the terminal from the tank, which contains the brake fluid. This is necessary so that the ECU does not display error messages. Then all fluid contained there is drained from the brake system.

This is done with syringes and tubes. Part of the fluid will not leave the system, so a rag will be required to remove possible streaks.

Allpipelines that have been disconnected must be plugged. Next remove the GTZ. After dismantling the cylinder, the old sealing parts are removed, and the cuffs are also removed from the housing. Then the seats of the sealing parts are cleaned of dust and dirt.

Conclusion

The brake system is an important part of any car. With the help of repair kits, you can quickly and inexpensively restore the main parts of the system that most often fail. The main thing is to remember about timely updating and, if necessary, complete replacement of the master brake cylinder repair kit or other important components of your car.