EXERCISE: Change rear drum brakes

DESCRIPTION: The objective of this practice is the study of the brake drum receiving element and the replacement of damaged parts of the drum brake

PRECAUTIONS:• Brake fluid is very corrosive and attacks vehicle paint.• Brake fluid is very danges for eyes• Clean all anchor, drum and others with water or some type of solvent that will dry out all the braking elements.• The dust from the brake system is poisonous and may be removed with compressed air. • To clean the brake system you may only use alcohol. • Avoid damaging the drum.

NOTE!Use the manual, AutoData or other sources to find technical data and make reference to it on your Worksheet.

WORK ORDERExercise: Change of rear drum brakes

Date: 29.11.2016. Time: 730-935

Student: Josip Jurić and Filip Nikolić

Car data Clients data

Vehicle type: Volkswagen UP! 1.0 Name: Jakov Orešković

Registration: ŽU-580-BL Adress: Bana Jelačića 65

ID number: WVWZZZAAZFD094815 Zip code: 32 100

Year: 2013. Town: Otok

Engine code: CHYA Phone nr: 032 320 892

Color: white Mobile nr: 097 676 94 92

km nr: 42605 e-Mail: -

ACTIVITES: Replace rear drum brakes

1. Study of the Service instructions

2. Remove the wheel.

3. Visual inspection (whether there is corrosion on a fender or the brake pipes, whether there is oil on shock absorbers or brake pipes, whether the spring damper is correct, whether the hand brake cable is right and whether brake hoses are in good condition)

4. Remove the M6 screws (Torx) on the brake drum.

5. Raising self-adjusting conical brake pads.

6. Removing the brake drum.

7. Unscrewing the nut and remove rear bearing.

8. Remove the spring plates with pressure springs.

9. Visually check brake springs, wear of friction lining and oiled cylinder

10. Clean ABS ring and ABS sensor from dirt and metal particles.

11. Measure the thickness of the brake pads. The measured thickness is 2.5 mm. The replacement is necessary.12. Measure the diameter of the brake drum. The measured diameter is 199.9 mm and 199.8 mm. The drums

brake is correct.

13. Remove the brake mechanism. Unpin the hand brake cable.

14. Disassemble the brake mechanism.

15. Assembling the brake mechanism with new brake shoes.

16. Install the brake mechanism.

17. Raise the cone plate to reduce the distance between the brake pads.

18. Clean and degrease friction surfaces.

19. Install hub bearings and tightening nut.

20. Install the brake drum.

21. Tighten M6 screws which holds the brake drum (Torx).

22. Set the wheels and tighten the wheel screw.

23. Adjust compression brake shoes and parking brake.

24. Check the validity of the brake fluid. Brake fluid is correct.

25. Top up the brake fluid (0.1 l).

26. Check the amount and accuracy of coolant. Coolant is correct (-35°C) and there is enough liquid.27. Check the oil level in the engine and when the oil has been replaced. The engine has sufficient oil and does

not require replacement.

REMARKS:

- max. diameter of the brake drum is 201.5 mm (7.933'')

- the minimum thickness of the brake linings is 2.5 mm

- the torque bearing hub nut is 30 Nm

- the torque of screw drum brake M6 is 8 Nm

- the torque of the wheel screw is 120 Nm

- the torque of the bleeder screw is 5 Nm

- the torque of the nuts metal brake line is 14 Nm

- removal tool spring brake pads, hook 3438

USED PARTS AND MATERIALS: L IQUIDS:

- brake pads Engine oil: correct

- nut for rear bearing Oil quality: correct

Coolant: correct

Windscreen fluid: correct

Brake fluid: 0.1 l

Alcohol 0.2 l

TO BE F ILLED BY TEACHER!

Checked: Marked: Signature:

EVALUATION FORM FOR TEACHERS AND EXTERNAL EVALUATORS

Exercise: Change of rear drum brakes

Name of the student: Josip Jurić

Name of the teacher: Antun Babić, dipl.ing.

Name of the tutor: Tomislav Kuveždić

Date: 29.11.2016.

OUTCOMES YES NO

The student follows rules for Safety at work XThe student makes proper preparation for the work XThe student follows instructions written in the manual XThe student works with other colleagues XThe student applies economical work principles XThe student performs activities according to the requirements of the work task XThe student follows enviornmental regulations XThe student explain the work procedure XThe student shows motivation for professional progress XThe student implements professional communication X

EXTRA COMMENTS / REMARKS:no

Signature:

EVALUATION FORM FOR THE STUDENTExercise: Change of rear drum brakes

Name of the student: Josip Jurić

Name of the teacher: Antun Babić, dipl. ing.

Name of the tutor: Tomislav Kuveždić

Date: 29.11.2016.

OUTCOMES YES NO

I follow rules for Safety at work XI can make proper preparation for the work XI follow instructions written in the manual XI work with other colleagues XI apply economical work principles XI perform activities according to the requirements of the work task XI follow enviornmental regulations XI can explain the work procedure XI show motivation for professional progress XI can implement professional communication X

EXTRA COMMENTS / REMARKS:no

Signature:

EVALUATION FORM FOR TEACHERS AND EXTERNAL EVALUATORS

Exercise: Change of rear drum brakes

Name of the student: Filip Nikolić

Name of the teacher: Antun Babić, dipl.ing.

Name of the tutor: Tomislav Kuveždić

Date: 29.11.2016.

OUTCOMES YES NO

The student follows rules for Safety at work XThe student makes proper preparation for the work XThe student follows instructions written in the manual XThe student works with other colleagues XThe student applies economical work principles XThe student performs activities according to the requirements of the work task XThe student follows enviornmental regulations XThe student explain the work procedure XThe student shows motivation for professional progress XThe student implements professional communication X

EXTRA COMMENTS / REMARKS:no

Signature:

EVALUATION FORM FOR THE STUDENTExercise: Change of rear drum brakes

Name of the student: Filip Nikolić

Name of the teacher: Antun Babić, dipl. ing.

Name of the tutor: Tomislav Kuveždić

Date: 29.11.2016.

OUTCOMES YES NO

I follow rules for Safety at work XI can make proper preparation for the work XI follow instructions written in the manual XI work with other colleagues XI apply economical work principles XI perform activities according to the requirements of the work task XI follow enviornmental regulations XI can explain the work procedure XI show motivation for professional progress XI can implement professional communication X

EXTRA COMMENTS / REMARKS:no

Signature: