GM Century/Lumina/Grand Prix/Intrigue 1997-2000

Basic Operating Principles

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Hydraulic systems are used to actuate the brakes of all automobiles. The system transports the power required to force the friction surfaces of the braking system together from the pedal to the individual brake units at each wheel. A hydraulic system is used for two reasons.

First, fluid under pressure can be carried to all parts of an automobile by small pipes and flexible hoses without taking up a significant amount of room or posing routing problems.

Second, a great mechanical advantage can be given to the brake pedal end of the system, and the foot pressure required to actuate the brakes can be reduced by making the surface area of the master cylinder pistons smaller than that of any of the pistons in the wheel cylinders or calipers.

The master cylinder consists of a fluid reservoir and a double cylinder and piston assembly. Double type master cylinders are designed to separate the front and rear braking systems hydraulically in case of a leak.

Steel lines carry the brake fluid to a point on the vehicles frame near each of the vehicles wheels. The fluid is then carried to the calipers and wheel cylinders by flexible tubes in order to allow for suspension and steering movements.

On drum brake systems, now being used on only the rear wheels of some cars, each wheel cylinder contains two pistons, one at either end, which push outward in opposite directions.

In disc brake systems, the cylinders are part of the calipers. One cylinder in each caliper is used to force the brake pads against the disc.

All pistons employ some type of seal, usually made of rubber, to minimize fluid leakage. A rubber dust boot seals the outer end of the cylinder against dust and dirt. The boot fits around the outer end of the piston on disc brake calipers, and around the brake actuating rod on wheel cylinders.

The hydraulic system operates as follows: When at rest, the entire system, from the piston(s) in the master cylinder to those in the wheel cylinders or calipers, is full of brake fluid. Upon application of the brake pedal, fluid trapped in front of the master cylinder piston(s) is forced through the lines to the wheel cylinders. Here, it forces the pistons outward, in the case of drum brakes, and inward toward the disc, in the case of disc brakes. The motion of the pistons is opposed by return springs mounted outside the cylinders in drum brakes, and by spring seals, in disc brakes.

Upon release of the brake pedal, a spring located inside the master cylinder immediately returns the master cylinder pistons to the normal position. The pistons contain check valves and the master cylinder has compensating ports drilled in it. These are uncovered as the pistons reach their normal position. The piston check valves allow fluid to flow toward the wheel cylinders or calipers as the pistons withdraw. Then, as the return springs force the brake pads or shoes into the released position, the excess fluid reservoir through the compensating ports. It is during the time the pedal is in the released position that any fluid that has leaked out of the system will be replaced through the compensating ports.

Dual circuit master cylinders, used on all modern cars, including your GM W-Body vehicle, use two pistons, located one behind the other, in the same cylinder. The primary piston is actuated directly by mechanical linkage from the brake pedal through the power booster. The secondary piston is actuated by fluid trapped between the two pistons. If a leak develops in front of the secondary piston, it moves forward until it bottoms against the front of the master cylinder, and the fluid trapped between the pistons will operate the rear brakes. If the rear brakes develop a leak, the primary piston will move forward until direct contact with the secondary piston takes place, and it will force the secondary piston to actuate the front brakes. In either case, the brake pedal moves farther when the brakes are applied, and less braking power is available.

The W-Body vehicles covered by this guide use proportioner valves which are threaded into the master cylinder. They limit the outlet pressure to the rear brakes after a predetermined rear input pressure has been reached. This is used when less rear apply force is needed to obtain optimum braking and to prevent rear wheel lock-up on vehicles with light rear wheel loads. His feature maintains a proper brake force "balance" during all braking maneuvers.

The hydraulic system may be checked for leaks by applying pressure to the pedal gradually and steadily. If the pedal sinks very slowly to the floor, the system has a leak. This is not to be confused with a springy or spongy feel due to the compression of air within the lines. If the system leaks, there will be a gradual change in the position of the pedal with a constant pressure. Check for leaks along all lines and at wheel cylinders. If no external leaks are apparent, the problem is inside the master cylinder. GM recommends that the brake lines and hoses be checked at least twice a year.

DISC BRAKES



Disc brake systems use a disc (rotor) with brake pads positioned on either side of it. Braking effect is achieved in a manner similar to the way you would squeeze a spinning phonograph record between your fingers. The disc (rotor) is a casting, usually with cooling fins between the two braking surfaces. This enables air to circulate between the braking surfaces making them less sensitive to heat buildup and more resistant to fade. Dirt and water do not affect braking action since contaminants are thrown off by the centrifugal action of the rotor or scraped off the by the pads. Also, the equal clamping action of the two brake pads tends to ensure uniform, straight line stops. Disc brakes are inherently self-adjusting. There are three general types of disc brake:



A fixed caliper
 
A floating caliper
 
A sliding caliper
 

The fixed caliper design uses two pistons mounted on either side of the rotor (in each side of the caliper). The caliper is mounted rigidly and does not move.

The sliding and floating designs are quite similar. In fact, these two types are often lumped together. In both designs, the pad on the inside of the rotor is moved into contact with the rotor by hydraulic force. The caliper, which is not held in a fixed position, moves slightly, bringing the outside pad into contact with the rotor. There are various methods of attaching floating calipers. Some pivot at the bottom or top, and some slide on mounting bolts. In any event, the end result is the same.

All the vehicles covered in this guide employ the sliding caliper design.

DRUM BRAKES



Drum brakes use two brake shoes mounted on a stationary backing plate. These shoes are positioned inside a circular drum which rotates with the wheel assembly. On these vehicles, the shoes are held in place by one large retractor spring. This allows the brake shoes to slide toward the drum (when the brake are applied) while keeping the linings and drums in alignment. The shoes are actuated by a wheel cylinder which is mounted at the top of the backing plate. When the brakes are applied, hydraulic pressure forces the wheel cylinder's pistons outward. Since the small projections on the brake shoe bear directly against the wheel cylinder pistons, the tops of the shoes are then forced against the inner side of the drum.

The W-Body vehicles covered by this guide may have either rear disc or drum brakes, depending on the vehicle, model and options. On these vehicles, the drum brake is a leading/trailing design. In the leading/trailing brake, the force from the wheel cylinder is applied equally to both shoes. Torque from the brake shoes is transferred through the backing plate, to the axle flange. Adjustment is automatic when the brakes are applied. When pressure within the wheel cylinder is relaxed, return springs pull the shoes back away from the drum.

Most modern drum brakes are designed to self-adjust themselves during application when the vehicle is moving in reverse. This motion causes both shoes to rotate very slightly with the drum, rocking an adjusting lever, thereby causing rotation of the adjusting screw.


WARNING
Clean, high quality DOT 3 brake fluid is essential to the safe and proper operation of the brake system. You should always buy the highest quality brake fluid that is available. If the brake fluid becomes contaminated, drain and flush the system and fill the master cylinder with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. NEVER use DOT 5 (silicone) brake fluid in these vehicles.

 
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