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technical manual
light vehicle
Technical Manual- LIGHT VEHICLE - 2
Content
A World-Class Company .................................................................. 03
Friction Material Features ............................................................... 05
Stopping Distance ......................................................................... 06
The Brake and the Physics .............................................................. 06
Brake Systems .............................................................................. 08
Disc Brake Pads Replacement ........................................................... 09
Brake Fluid ................................................................................. 09
Grinding Discs .............................................................................. 10
Grinding Drums ............................................................................ 10
ABS Systems ................................................................................ 11
Brake Most Common Failures ........................................................... 12
Failure Diagnosis ........................................................................... 13
Tips on Steering Problems ............................................................... 16
Instructions to bond Friction Materials to Metallic Surfaces ...................... 17
Conversion Table – Light Brake Linings ................................................ 18
Conversion Table - Brake Pads ......................................................... 18
Technical Manual- LIGHT VEHICLE - 3
A WORLD CLASS COMPANY
International Leadership and Technology
Established in 1954, Fras-le is engaged in the manufacturing of friction materials. Its business – Safety in Motion Control
- makes of it the largest company in Latin America and one of
the leading companies in the world in the Àeld.. It was the Àrst
friction material manufacturer in Brazil to obtain the ISO 9001
CertiÀcation. Fras-le has also achieved the ISO 14001 and the
ISO TS 16949. These certiÀcations conÀrm the company’s constant concern with quality, technology and environment.
Fras-le provides products with the quality of original equipment to ensure safety, efÀciency and quality to OEM companies and the Aftermarket. In its advanced Research and
Development Center – one of the best equipped labs in the
world – Fras-le has a chemical, physical and pilot lab that enable it to develop high-performance products. With its plant
in the State of Rio Grande do Sul, distribution centers in the
United States and Argentina, and trade ofÀces in Chile, Mexico, Germany, The Arab Emirates, South Africa and China,
the company maintains a trained team to meet the needs of
customers located throughout more than 70 countries on Àve
continents where the company is present. Fras-le is a Randon
Group company.
High Technology
Fras-le has the largest and best equipped lab in Latin
America to test its products, which are then delivered to
test Àelds, race courses and roads, where they are approved and released for production. The entire process is
followed up by Fras-le`s and OEM companies` engineers to
ensure that the Ànal product complies with the required
speciÀcations.
Research Lab
The Chemical Research Lab is in charge of analyzing the
raw-materials for the development of new products and
the improvement of existent material. At Fras-le, more
than 135 different types of raw-materials are used in the
production line. SpeciÀc methods of analysis are employed
in new alternative raw-materials until coming to the
compounds that make up the products.
Quality Assured by Raw-Materials
The raw-materials lab is responsible for analyzing over
135 different types of raw-materials accepted into the
company. It also supports production system processes and
develops new suppliers. These are the most important tasks
carried out by the raw-materials lab, which also develops,
certiÀes and audits the processes used by the suppliers in
order to maintain their already proven qualiÀcation levels
as Fras-le`s suppliers. The lab plays a very important role
for Fras-le to gain market share, as it assures the quality
of its products. This means that the raw-materials, the
productive process and the tests are crucial for the safety
of the products in any of their applications.
Technical Manual- LIGHT VEHICLE - 4
Assessment
All products being developed and those in the production
lines are tested in the Physical Lab, which integrates
the Research and Development Center. Different pieces
of equipment simulate real working conditions of rawmaterials in their different applications, being instrumental
in the improvement of the products until they reach the
Ànal quality required by consumers.
The lab operates in three working shifts, continually
running tests and assessing their results. The lab includes
the entire process of Fras-le`s products, from development
to assessment of the products in the market, from the
initial tests to the Ànal user through speciÀc tests.
More than 120 different types of trials are carried
out monthly in this Research and Development Center
which offers the most complete testing structure in Latin
America.
In Pilot Production, Quality is Assured.
In the Pilot Lab, samples are produced from customers`
new needs and requests, especially OEM companies of
vehicles. Experiments with new formulations are carried
out. If approved, they go through all test phases until they
reach the regular production lines. The Pilot Lab controls all
features associated to the development of these products.
At the beginning, Fras-le has not only absorbed technology
from well-known manufacturers of friction materials in the
world, both European and North-American , but has also
improved the global production modus operandi. Stateof-the-art equipment and the company’s own culture
and experience are the basic ingredients of Fras-le`s
philosophy: that of developing high quality products that
reÁect the tradition of its brand in the market. In addition
to developing its own technology, Fras-le also maintains
agreements and partnerships
Motion Control: Fras-le`s Mission
In addition to research, development of materials and
products, test Àelds are also very important to maintain
quality levels. During tests, products applied to vehicles go
through all situations they will possibly face when operating
in real situations, on the most diversiÀed road conditions.
The performance of the products is also strictly followedup by technicians who visit customers on a permanent
basis. These technicians give lectures, courses and instruct
retailers` clerks, mechanics and drivers so that they can use
the products safely.
Technical Manual- LIGHT VEHICLE - 5
FRICTION MATERIALS FEATURES
Mechanical Strength
Friction material must have a mechanical strength
sufÀcient to stand the efforts inherent to the application
it is designed for. Among mechanical efforts, we highlight
Compression (rubbing against the friction surfaces) and
Shearing (which results from tangential forces caused by
rotation movements).
Estabilidad Dimensional
Todo material de fricción calentado y rápidamente
enfriado debe mantener su forma y dimensiones lo menos
alteradas posible.
HEATING
Braking actions at every half minute,
from 90 to 0 km/ h.
0,50
COOLING OR RECOVERY
Braking actions at every 3
minutes, from 45 to 0 km/h.
0,40
0,30
0,20
0,10
Temperature ( Degrees Centigrade)
8th braking
7th braking
6th braking
5th braking
4th braking
th
3 braking
2th braking
300 250 220 200 180 150 120 100
th
1 braking
th
15 braking
th
14 braking
13th braking
th
12 braking
11th braking
th
10 braking
th
9 braking
8th braking
7th braking
th
6 braking
5th braking
th
4 braking
3rd braking
nd
2 braking
40ºC 100 160 190 210 230 250 270 290 310 320 330 340 345 350
1st braking
COEFFICIENT OF FRICTION
The coefÀcient of friction is the most important factor
in friction materials. Its value must be kept constant within
a certain temperature range.
A high coefÀcient of friction does not necessarily mean
quality in friction materials. Using the brake too hard
is sometimes as dangerous as lack of brake. The friction
stability is a crucial factor that depends on temperature,
speed, pressure and external factors. Lack of brake is not
necessarily caused by the friction material, but may be
caused by a failure in the hydraulic or air system.
Please see below the most important features involving
friction materials:
Durability
The useful life of friction materials is a very important
factor that depends on the quality of the friction material
selected for a certain application. One of the factors that
determines the durability of friction materials is temperature.
Friction materials are bonded by organic resins that
impose limitations on their working temperature. If the
brakes or clutches are constantly used in high temperatures,
wear on friction materials accelerates. Durability is
also affected by the geometry of the brake and clutch,
cast material and Ànish of the braking surfaces. A good
quality friction material must be also a thermal insulator
to protect the deepest parts from the high temperatures
generated during brake and cluck applications. Wear
on friction materials is necessary to renew the friction
surface, otherwise glazing may occur. On the other
hand, this renewal should not happen too quickly, at
the risk of affecting the durability of friction materials.
Sometimes,
complaints
about
durability
are
due to problems related to the dimension of the
brake ( if the drum heats too much, the working
conditions have not been
properly designed).
Technical Manual- LIGHT VEHICLE - 6
STOPPING DISTANCE
Basic Concepts in Brakes
People react differently to obstacles or to diverse
situations on trafÀc. When they are walking on roads, they
may react differently and unexpectedly from when they
are walking on streets. Therefore, it is necessary to get
familiarized with the driver`s behavior when driving on
different roads.
Braking a vehicle basically depends on three factors:
the vehicle, the road and the driver. A higher or lower
braking efÀciency basically depends on the combination of
these three factors.
Please see below a table that shows stopping distances
in relation to the vehicle’s speed:
SPEED IN Km/h
STOPPING DISTANCE IN METERS
GOOD BRAKES
BAD BRAKES
20
3,1
4,0
30
6,9
9,0
40
12,3
16,0
50
19,3
25,0
60
27,7
36,0
70
37,8
49,0
80
49,3
64,0
90
62,5
81,0
100
77,2
100,0
Force:
all action capable to change the speed of a
body.
Area: surface area measurement.
Pressure:
ratio between the applied force and the
surface area.
Kinetic energy: energy of a body while in motion (Àg.
01).
Kinetic
Energy
Heat
Àg. 01
CoefÀcient of Friction:
ratio of friction force to
the normal force.
Wear: reduction in material caused by friction.
Braking Force:
force resulting from the brake
mechanism contrary to the motion of the vehicle. The
higher the compression, the higher the braking force.
Fuerza de Frenada:
THE BRAKE AND
THE PHYSICS
An hydraulic brake works based on the Pascal`s law.
“ Pressure applied to a conÀned Áuid is transmitted
undiminished throughout the conÀning vessel of the
system”.
Example: By using an injection syringe (conÀning vessel),
we can clearly exemplify the law: let`s block the outlet
hole and press the piston. There will be pressure at all
contact points of the liquid.
Es la fuerza resultante del
mecanismo de freno en sentido contrario al movimiento
del vehículo. Cuanto mayor la compresión, mayor la fuerza
de la frenada.
Fade: reduction in stopping power (i.e. the reduction of
friction between the brake pad /brake linings) caused by a
buildup of heat in the braking surfaces.
Technical Manual- LIGHT VEHICLE - 7
Considerations on Brakes
The Equipment
The Brake Stops the Wheel and the Ground
Stops the Vehicle: A vehicle in motion means that
Master Cylinder:
the wheels are turning. Brakes are not designed to stop
the vehicle, but slow down the wheels rotation until they
stop completely. Assuming a vehicle has brakes functioning
perfectly but the tires are poor and the road is wet: after
applying the brakes, we guarantee that the wheels will
stop, but we cannot guarantee that the vehicle will stop
together with the wheels.
The master cylinder activates and controls the braking
process. When applying the brake pedal, the piston
compresses the Áuid in the compression chamber, building
up pressure throughout the hydraulic circuit of the system
( Àg. 02).
Brakes Are a Set: Therefore, we should treat them
as such. Their performance depends on the performance of
their parts taken as whole.
Brakes Are a Safety Item: If a vehicle’s component
breaks while in motion, you still can manage to stop the
vehicle, but if there is a brake failure, the vehicle will
stop through collision.
Friction X Brake:
Whenever a body tries to slide
over another one, a force called FRICTION prevents it from
sliding.
Àg. 02
Wheel Cylinder
When you apply the brakes, the Áuid compresses the
pistons, which push the brake shoes against the drum (
Àgure 3).
Sliding = Heat: If we slide down a rope, our hands will
burn, but if we go down normally (not sliding) our hands
will not burn.
Gases X Compressibility: an inÁated tire suffers
deformations against weight exerted on it, that is, gases
ARE COMPRESSIBLE.
Liquids X Compressibility:
If we completely inÁate a tire with water under
pressure, the result will be a rigid tire that will not suffer
deformations when weight is exerted on it. This means
liquids ARE NOT COMPRESSIBLE.
Good performance of the brake system depends
on preventive maintenance. Carry out preventive
maintenance every six months and your brakes will always
work properly.
Àg. 03
Brake Caliper
Component that needs a disc that, when grasped,
enables the piston to press the pads against the disc,
causing friction.
Servo-Brake
Equipment designed to provide more comfort to the
driver when applying the brake pedal. The servo-brake
uses atmospheric pressure that, combined with the vacuum
generated by the engine, increases the force exerted on
the pedal.
Brake Disc
Metallic part with a Áat and parallel surface that resists
to the compression of the pads exerted by the hydraulic
system.
Technical Manual- LIGHT VEHICLE - 8
BRAKE SYSTEMS
Advantages of Disc Brakes:
Hydraulic Brake
Distributes the force by means of pressure in a Áuid
and acts on the brake shoes by means of pistons ( Àg. 4).
Wheel cylinder
Brake Lining
Drum
Self-adjustable, Áat braking surface, higher cooling and
cleanliness, easy maintenance, and uniform braking even
in abrupt braking actions.
Due to these advantages, there has been a trend to
replace drum brake systems by disc brake systems in all
vehicles ( including the heavy line vehicles). For this to
be fully implemented, pad materials should be developed
to stand high temperatures, as their braking area is small.
Studies have also been carried out to improve their thermal
conductibility (fan), good mechanical resistance and high
resistant to friction, thermal fatigue, and corrosion.
Brake shoe
Àg. 04
Àg. 05
Disc Brake
In this brake, the braking force is obtained by pressing
two brake pads against the brake disc. The disc must be
submitted to equal forces on both lateral faces so the disc
and the pads may wear equally (Àg. 05). There are two
versions of disc brakes: with Àxed caliper (Àgure 06) and
two pistons; and the Áoating type ( Àgure 07) with one
piston only. In the two-piston type, each piston activates
one brake pad against the disc face. For being less cooled
by the movement of the vehicle, the piston located on the
wheel side dissipates the heat generated during braking
action through the caliper body and the brake Áuid. As
heat dissipation is lower in this type of construction, a
Áuid proper for high temperatures must be used with this
brake.
Fixed Caliper
Floating Caliper
pinça flutuante
pinça fixa
Àg. 06
Àg. 07
Technical Manual- LIGHT VEHICLE - 9
DISC BRAKE PADS REPLACEMENT
When replacing disc brake pads, we recommend that
you follow the procedure below ( Fig. 08):
5º) Replace the pads and check the condition of the
springs. If necessary, replace the springs;
6º) We recommend that you use brake Áuid proper for
operation in high temperatures;
7º) Once you complete the procedure, check the brake
pressure;
8º) Apply the brakes 6 to 8 times from 60 km/h up to
40 km/h and apply the brakes again 6 to 8 times from 40
km/h until the vehicle comes to a complete halt. This will
allow pre-burnishing to take place. We remind you that a
satisfactory output of the material depends on its initial
behavior;
9º) Soon after replacing the pads, use the brakes
moderately. This will allow a perfect burnishing between
the friction material and the brake disc.
1º) Clean the disc, mainly the friction surfaces. If
necessary, grind both faces simultaneously so they can
have parallel faces. Remove any particles of carbon dust
left by the machining process with industrial alcohol;
2º) Clean the brake caliper where the pads are with a
steel brush;
3º) With a proper tool, move the piston away from the
set by Àrst opening the bleeding screws. This will allow
the pads to be introduced easily. Do not use poor quality
pads;
4º) In case the pistons are gripped, replace the caliper
repair kits;
Brake disc
Bleeding Screw
Housing
Bleeding screw cap
Rataining Pin
Key
Cushioning
plate
Cushioning
spring
Brake pads
Dust-shield
Retaining
ring
Piston
Piston retaining ring
Àg. 08
BRAKE FLUID
To keep the brake Áuid in good conditions, never
complete the level of the reservoir. If Áuid level is low,
check the cause, which may be leak or excessive wear on
the pads. If you complete the level, good Áuid will mix
with a contaminated Áuid, changing its properties and
not offering the ideal working conditions. Contamination
of the Áuid by humidity ( water) will not only cause the
brakes to operate in higher temperatures for a longer
time ( wearing down the pads more rapidly) but will also
damage the metallic parts of the system, which, in contact
with humidity, will cause corrosion, compromising the
efÀciency of the system.
Technical Manual- LIGHT VEHICLE - 10
GRINDING DISCS
The friction surfaces of brake discs affect directly
the useful life of the pads. Cracks, thermal Àssures and
grooves must be removed by grinding these surfaces
whenever you feel they need (use your hands to feel
it). On the other hand, grind brake discs only as far as
the safety limit recommended by manufacturers. We
recommend that you replace them whenever the actual
thickness of the disc is equal or lower than the dimension
engraved on the disc.
GRINDING DRUMS
RIVETING TABLE
DIAMETER OF THE VEHICLES – mm
VEHICLES` MAKE
Regular Belt
Oversized Belt (1)
229,0
231,6
280,0
281,0
180,0
181,0
185,0
186,0
228,0
229,0
180,0
181 (*)
200,0
201,0
203,0
204,0
229,0
230,0
Oversized Belt (2)
RIVETING TYPE
DIMENSIONS – mm
A
B
C
4-3
3,6
4,8
8,0
4-4
3,6
6,4
8,0
4-5
3,6
8,0
8,0
4-6
3,6
9,5
8,0
182 (*)
4-7
3,6
11,0
8,0
202,0
5-4
3,6
6,4
9,5
5-5
3,6
8,0
9,5
231,6
5-6
3,6
9,5
9,5
231,6
5-7
3,6
11,0
9,5
254,0
255,6
7-3
4,8
4,8
9,5
280,0
281,6 (**)
7-4
4,8
6,4
9,5
305,0
306,6
7-5
4,8
8,0
9,5
330,0
331,6
7-6
4,8
9,5
9,5
180,0
181,0
7-7
4,8
11,0
9,5
200,0
201,0
7-8
4,8
13,0
9,5
203,0
204,6
7 - 10
4,8
16,0
9,5
222,0
223,6
7 - 12
4,8
19,0
9,5
229,0
230,6
8-8
4,8
13,0
13,0
280,0
281,6
8 - 10
4,8
16,0
13,0
305,0
306,6
8 - 12
4,8
19,0
13,0
330,0
331,6
8 - 14
4,8
22,0
13,0
200,0
201,0
202,0
8 - 16
4,8
25,0
13,0
230,0
231,0
232,0
248,0
249,0
250,0
250,0
251,0
252,0
LADA
250,0
251,0
MB
254,0
255,0
10 - 8
6,4
13,0
13,0
PEUGEOT
254,0
255,0
10 - 10
6,4
16,0
13,0
229,0
230,6
10 - 12
6,4
19,0
13,0
248,0
249,0
10 - 14
6,4
22,0
13,0
254,0
255,6
10 - 16
6,4
25,0
13,0
160,0
161,0
11 - 5
4,0
8,0
8,0
305,0
306,6
13 - 10
8,0
16,0
16,0
180,0
181,0
13 - 12
8,0
19,0
16,0
200,0
201,0
13 - 14
8,0
22,0
14,0
203,0
204,0
13 - 16
8,0
25,0
14,0
230,0
231,0
232,0
8 x 15
8,0
15,0
16,0
248,0
249,0
250,0
8 x 16
8,0
16,0
16,0
250,0
251,0
252,0
8 x 18
8,0
18,0
16,0
8 x 20
8,0
20,0
16,0
8 x 22
8,0
22,0
16,0
VOLVO
6,2
19,0
12,5
CHRYSLER
FIAT
FORD
GM
GURGEL
PUMA
RENAULT
TOYOTA
VW
* Except for P/N FC/66
* Except for P/N 1219
187,0
202,0
RIVETING TYPE
10 - 6
250,0
182,0
DIMENSIONS - mm
A
B
C
6,4
9,5
13,0
Technical Manual- LIGHT VEHICLE - 11
ABS SYSTEM
In addition to all traditional brake components, the
vehicle may also be equipped with the ABS system, which
offers many advantages to the driver in terms of safety.
Anti-Locking Braking System (ABS) is designed to
prevent the wheels from locking while braking, due to
heavy braking, in any braking condition, ground or tire,
especially on slippery surfaces. The system allows lateral
friction to be maintained on the wheels being decelerated,
even during the total application of the brakes. As a result,
the stability and steering condition of the vehicle are
guaranteed within physical limits. When braking friction
occurs between the tire and the ground, the deceleration
of the vehicle and the stopping distance are optimized.
An anti-locking braking system is a re-feeding system
that controls the braking pressure in response to the
average deceleration of the vehicle to prevent the wheels
from locking. The system basically consists of the following
parts:
- Wheel speed sensor: captures the variation of wheel
rotation and sends a signal to the controller;
- Control Unit: receives the signal from the sensor,
interprets it and sends the decision to the modulator;
- Modulator: controls the brake pressure as a result of
the signals received.
Brakes equipped with ABS do not require special friction
materials. The original or regular friction material can be
used.
The wheel rotation sensors inform the control unit if
there will be a locking action at one or more wheels. The
control unit (modulator) will stop such a locking by giving a
set of signals to the hydraulic control, which will regulate
the brake oil pressure individually, in each wheel.
This way, the driver can brake the vehicle heavily
without locking the wheels, maintaining steering control
with ease and safety at the shortest distance traveled.
The ABS system also allows the driver to hit the brakes
fully on curves at high speeds, even on wet or slippery
roads without the fear of skidding or loss of control.
Servo
Brake
Drum
Fluid
Reservoir
Pressure
Regulating
Valve
Pad
Brake shoes
Disc
Master
Cylinder
Disc
Brake
Wheel
Cylinder
Brake lining
Technical Manual- LIGHT VEHICLE - 12
BRAKE MOST COMMON FAILURES
PROBLEM
CAUSE
Wet Brake Linings
Air in the Circuit.
SOLUTION
Hit slightly the brake pedal with the vehicle in motion. This will make the brake
linings to dry.
Bleed the circuit.
Low pressure in the brake Áuid.
LACK OF EFFICIENCY
Check the Áuid level and possible leaks.
Too much play between the drum and the
Worn brake linings, requiring the brakes
lining. If the defect continues, replace
to be applied several times before it enthe brake linings. Check the retainers and
gages.
check the Áuid for leaks.
Diaphgram is leaking.
Replace the diaphgram.
The grease must be removed with industrial alcohol. Do not use thinner, or fuel,
Grease in the drums, damaged retainers or
as they can compromise the resistance of
Áuid leak.
the brake linings. Check the retainers and
inspect for Áuid leaks.
Improper brake linings.
Replace them.
Replace the brake linings by following the
Loose brake linings or out of center.
riveting procedures.
Brake linings contaminated with grease, oil Replace the brake linings and correct posor brake Áuid.
sible Áuid leaks.
FLUID LEAK
TOO MUCH PLAY ON PEDAL
THE BRAKES HEAT
LOW PEDAL
Brake Fluid Quality.
With the vehicle stationary, hit the brake
pedal heavily and check all Áexible hose
junctions and piping throughout the circuit.
Change the Fluid.
Worn Cylinder Rubber.
Replace the rubber.
Holes in the piping or Áexible hoses.
Edges of brake hoses are swelled or cracked.
Check and replace the brake hoses.
There is no play between the brake shoe Adjust the play between the brake lining
and the drum.
and the drum.
If the problem is only on the rear wheels, it
is possible that the hand brake is not well
Hand Brake.
adjusted and is forcing the linings against
the drum, even when the lever is not being
used.
Improper hub caps are being used.
Remove the hub caps.
The return valve is damaged. Do not open
The Fluid does not return.
alter applying the brakes. Unclog the
oriÀces in clogged piping.
Check for leaks or worn pads and change
Lack of Fluid.
the Áuid.
There is air in the piping.
Bleed the piping.
Weak brake hoses: they easily expand.
Gripped pedal mechanism or activating
lever of master cylinder.
PEDAL DOES NOT RETURN
Cylinder pistons are blocked.
Replace the hoses.
Check pedal or lever mechanism
Correct the defect by leaving the pistons
free to move.
Bent brake hoses and broken connections.
Replace the brake hoses or connections.
Glazed linings or pads.
Replace the springs. Replace linings or
pads.
Wet linings.
Dry them by pressing the pedal with the vehicle in motion.
NOISY BRAKES
Technical Manual- LIGHT VEHICLE - 13
FAILURE DIAGNOSISS
Aiming to make the diagnosis and solution of failures
in the brake system easier, you will Ànd below references
to the most common causes of brake failure. It does not
PROBLEM
CAUSE
SOLUTION
Excessive wear.
Replace the disc or grind the surface
Internal leak: replace the internal repair kit when the brake caliper does not
show signs of internal corrosion, otherwise replace the hydraulic assy.
External leak: locate the leak and replace the defective components.
Replace the repair kit or components.
Open them, replacing the defective parts.
Replace the internal repair kit when the brake caliper does not show signs of
internal corrosion, otherwise replace the hydraulic assy.
Internal or external Áuid leak
Leak or wear.
Kinked brake lines.
THE VEHICLE
DOES NOT STOP
mean they are the only possible causes. For each cause a
solution is presented.
Engaged hydraulic system pistons.
Poor quality brake linings and pads.
Brake linings and pads contaminated
with grease or oil.
Overheated brake linings and pads (brakes
are applied repeatedly and continually).
Brake linings and pads not burnished.
Glazed brake linings and pads.
Moldy brake linings.
Replace the brake linings or brake pads
Friction materials ( brake linings and pads) are responsible for decelerating the wheels. Therefore, any damage or
irregularity in the friction material affects directly the stopping distance. When the brake drum is not well adjusted,
pressurization takes place slowly, the brake pedal has a longer run and it is difÀcult to stop the vehicle. In this case,
adjust the brakes correctly. Lack of pressurization or difÀculty to pressurize the brakes on the wheels may have different
causes as well.
NOTE: Excessive load or passengers will require a greater effort from both, the driver and the brake system, not
allowing for a safe braking action at a shorter stopping distance.
PROBLEM
BRAKE PEDAL
TREPIDATION
CAUSE
Brake discs with non-parallel friction surfaces. This
happens due to poor grinding or poor quality of the
discs.
Out-of-shape brake drum.
Misalignment during rectiÀcation.
SOLUTION
Grind correctly or replace the discs.
Grind again or replace the brake drum.
This usually happens when the brake Áuid is forced to return to the brake pump due to problems in the wheel
brakes.
PROBLEM
CAUSE
SOLUTION
Adjust well the brake-servo inlet rod.
VEHICLE WITH
BLOCKED
WHEELS.
Inlet rod of servo-brake is improperly adjusted.
Inlet rod adjusting screw, which activates
the master cylinder, is not adjusted.
Brake hose is damaged, making pressure relief more
difÀcult in the brakes.
Regulate the adjusting screw.
Replace the defective brake hoses.
This happens when the wheels are overheated or when the wheels do not turn when the vehicle is suspended.
Technical Manual- LIGHT VEHICLE - 14
PROBLEM
CAUSE
Too much play between the pedal brake lever and
the servo-brake inlet rod, or between the outlet rod
( servo) and the master cylinder.
Air in the hydraulic circuit
Internal or external leak somewhere in the circuit.
Overheated brake disc.
Old Áexible hoses or of poor quality. They do not
stand the pressure and get swelled.
PEDAL GOES TOO
Drum
with
internal diameter out of speciÀcation
DEEP DOWN
(many times ground) with too thin walls. They do not
stand the brake shoes force and may break.
Non-burnished brake linings and pads, since there is
a signiÀcant loss of contact area between the friction
material and the friction surface of the disc or drum.
Automatic adjusting mechanism of the brake is engaged, leaving the brake linings far from the drum.
Poor quality Áuid or contaminated with water. The
Áuid vaporizes too easily, generating gases in the
circuit.
SOLUTION
Correct the play in the rods.
Bleed the brake system.
Internal leak: Replace the internal repair kip when the brake caliper does
not show signs of internal corrosion, otherwise, replace the hydraulic assy.
External leak: locate the leak and replace the defective components.
Avoid using the brake too much.
Replace the Áexible hoses.
Replace the brake drum.
A perfect burnishing of the friction material takes place at the extent the
brakes are used (alter approximately 500 km (in the city).
Repair and lubricate the automatic adjusting mechanism.
Change all the brake Áuid.
To engage the brakes, the pedal must go to a certain point. This varies according to the vehicle and to each
manufacturer’s speciÀcations. If the brake needs to go too deep down, it is a sign that there are problems.
PROBLEM
CAUSE
THE VEHICLE
PULLS TO ONE
SIDE
Unequal adjustment of the drum brakes in the front
axle.
During replacement of brake linings and pads, make
sure not to contaminate them with grease or oil, as
this causes imbalanced braking actions.
Discs or drums with wrong diameter / thickness.
Non-matching brake linings and pads ( different
types).
The hydraulic pressure does not reach one of the
brake sides due to an obstruction in
the piping or Áexible hoses.
Wheel cylinder or disc brake caliper
is engaged in one of the sides.
Brake retaining springs with pressure loss in one of
the sides.
SOLUTION
Adjust the drum brake.
Replace the contaminated component.
Grind or replace the disc or drum.
Use the correct part during replacement.
Unclog the piping or Áexible hoses, replacing the damaged parts.
Replace the internal repair kit when the brake caliper does not show signs of
internal corrosion, otherwise replace the hydraulic assy.
Replace the springs.
Any difference between the left and the right side in the front axle, whether in the suspension or brakes, results
in the vehicle pulling to one side.. The Àrst measure to avoid this problem is servicing the brakes in each axle, making
sure to keep the same conditions in both sides.
Watch the following factors, as they may contribute to the defect and are not part of the brake system:
-Badly calibrated tires or of different types;
-Irregular steering system ( convergence or Caster angle out of speciÀcation);
-Bearings of front wheel hub are damaged or loose;
-Front suspension or steering bar are loose or damaged.
Technical Manual- LIGHT VEHICLE - 15
PROBLEM
CAUSE
Locked master (cylinder oxidation).
THE BRAKE
PEDAL IS TOO
HARD.
Brake linings and pads are glazed or of poor quality.
Engaged pedal articulation, causing
the pedal to get too hard.
Kinked brake lines.
Obstructed brake hoses.
Locked wheel cylinder or brake caliper.
Damaged servo brake.
SOLUTION
Replace the internal repair kit when the brake caliper does not show signs of
internal oxidation, otherwise replace the hydraulic assy.
Replace the brake linings and pads.
Disengage the pedal articulation.
Open them and replace the damaged components.
Replace the brake hose.
Replace the internal repair kit when the brake caliper does not show signs of
internal oxidation, otherwise replace the hydraulic assy.
Repair or replace the brake servo.
Problems in the servo brake require greater effort to apply the brakes, since there is leak in the servo and the hoses
or air inlet Àlters are obstructed. Under any of these conditions, the system does not work, causing too much effort at
the pedal. Despite this, the brakes are still working.
PROBLEM
CAUSE
VEHICLE WITH
LOCKED WHEEL
Disc brake retaining ring is dry. This prevents the
piston from returning.
Improperly adjusted brake shoes or
parking brake cable.
Out-of-shape drum.
Drum brake springs show fatigue or are broken.
Damaged return valve in the power brake booster.
SOLUTION
Replace the repair kit of the disc brake caliper.
Adjust the brake properly.
Grind or replace the brake drum.
Replace the springs.
Replace the return valve.
This happens when the wheels are overheated or when the wheels do not turn when the vehicle is suspended.
PROBLEM
CAUSE
SOLUTION
Replace the brake linings or brake discs.
Check if there is play or damaged pieces. Replace if necessary.
NOYSE BRAKES
Glazed brake linings, worn discs or of poor quality
Play or wear.
Loose, wet, out-of-center or
contaminated brake linings.
Improperly assembled brake shoes or brake linings.
Improperly-adjusted springs or showing fatigue.
Replace the pads or linings.
Assemble the linings correctly.
Replace the drum brake springs.
This usually happens when the brake pads or linings are glazed, or when they are contaminated. Discs and drums in
poor conditions also may cause noise.
PROBLEM
CAUSE
ABRUPT
BRAKING
ACTIONS
Defective internal mechanism of the
servo-brake.
Brake linings or pads with coefÀcient of
friction higher that the one designed for
the vehicle.
SOLUTION
Repair or replace the servo brake.
Replace the brake linings or pads.
Brakes are designed to carry out safe and comfortable braking actions. When applying the brakes, the effect should
not be aggressive.
Technical Manual- LIGHT VEHICLE - 16
TIPS ON STEERING PROBLEMS
Brake Pedal:
: the pedal travel should not be longer
than 5,0 cm or 2,5 cm in vehicles equipped with servo
brake. When the pedal is too low or there is no resistance,
the hydraulic circuit may be defective or bubbles may
be building up in the system. If the pedal gets too hard /
heavy, this means the servo brake must not be working for
some reason.
With the engine on, put your foot on the brake with medium
force for 15 seconds: if the pedal does not move, the brake
is in good conditions.
Whenever You Replace Brake Linings or
Pads: Grind the discs or drums or have them replaced.
This will allow for a better burnishing, improving the
efÀciency of the braking actions, increasing the useful life
of the linings and pads, and eliminating noises.
Wheel cylinder
Brake Lining
Glazed Brake Pads:
if there is overheating in the
system in the beginning of the pads` useful life, glazing
may occur. This can be usually avoided with the preburnishing between brake pads and disc, or through a
thorough maintenance in the system. Every 5,000 km,
check the brake pads and inspect the brake system every
10,000 km. The minimum thickness should be 2 mm in the
brake pads and 0,5 mm in the brake linings at the upper
edge of the rivets.
Drum
Brake Shoe
If the Front Wheels Lock: the vehicle continues
running but loses steering control. Some of the causes
may be: rear brake linings and pads improperly assembled,
worn or with oil; improperly adjusted slack adjuster;
worn or defective disc or drum and problems in the rear
hydraulic circuit.
If the Rear Wheels Lock: the vehicle loses stability
Brake Fluid:
For being hygroscopic, the brake Áuid
absorbs water in the hydraulic system, especially when it
is submitted to great efforts. Down hill and heavy trafÀc,
for example, are situations that generally overheat the
brakes, increasing the temperature to over 150° C. This
may cause air bubbles to build up in the brake system,
generating brakes failure and leading the driver to hit the
pedal in vain.
The brake Áuid must be changed according to the
manufacturer’s instructions.
and may slip. Some of the causes may be improperlyinstalled front pads, worn front pads, or even a defect in
the support of the front axle.
Stability and Skidding:
the vehicle should keep
on course after a braking action. If it does not do that,
there must be a failure in one of the sides of the brake
system: stuck cylinder pistons, defective or worn discs,
wrong brake pads, worn pads, contaminated with oil or
glazed.
Technical Manual- LIGHT VEHICLE - 17
INSTRUCTIONS TO BOND FRICTION MATERIALS
TO METALLIC SURFACES
Bonding friction materials on their metallic supports
requires a few cares.
The metallic surfaces that will contact the friction
materials must be free from any type of contamination.
Whenever it is possible, sandblast the surface or use any
other process to remove impurities without damaging the
surface.
A number of adhesives can be found on the market.
Follow the manufacturer’s instructions concerning bonding
and its application / curing processes.
As an example, please see below an extract on the
application of one type of bonding material:
EC 1099 Adhesive - 3M:
Application Process:
Remove any type of residue / impurity from the brake
shoe surface – where the brake lining will be installed.
Clean the brake shoe surfaces with alcohol or acetone.
Apply a uniform coat of adhesive on both, the brake
shoes and the brake linings, and wait for three minutes.
Position correctly the brake lining onto the brake shoe
by placing the set in a proper device that will keep the
brake lining pressed against the brake shoe. Take the set
to a pre-heated oven (150° C ( ± 5)) and keep it there for
about four ( 4) hours. Remove the set from the oven, allow
it to cool and remove possible surplus of adhesive from the
sides.
The information above must be updated according to
the adhesive manufacturer’s instructions.
Technical Manual- LIGHT VEHICLE - 18
Conversion Table – Light Brake Linings
FRAS-LE
BENDIX
BOSCH
COBREQ
FRAS-LE
855
1219
2006
2006-T
2011
2053-T
2080-T
2095
2121-T
8020
8049
CB/38
CB/39
HQ-127
HQ-139
LF 0127
LF 0139
LF 0118
LF 0121
LF 0147
LF 0148
LF 0122
LF 0146
LF 0149
0417
1219
CB/40
HQ-110
LF 0110
0200 / 0495
CB/41
CB/42
CB/43
CB/47
CB/48
CB/49
CB/51
CB/52
CB/55
FD/61-S/F
HQ-110C
HQ-107
HQ-106
HQ-108
HQ-128
HQ-145
LF 0110C
LF 0107
LF 0106
LF 0108
LF 0128
LF 0145
LF 0151
LF 0143
LF 0152
0207
FD/63-S/F
FD/64-S/F
FD/65
FD/66
FD/68
FI/90
FI/91-S/F
FI/96-S/F
LD/123-S/F
MB/156-S/F
RN/210
TY/252
TY/253
TY/254
VW/262
VW/264
VW/270
VW/271
VW/272
VW/273
VW/274
VW/275
VW/276
VW/277
VW/278
HQ-121
HQ-122
HQ-157
HQ-129
HQ-109
HQ-143
2006T
0457T
LF 0129
LF 0109
LF 0150
0211
BENDIX
BOSCH
COBREQ
HQ-116
HQ-117
LF 0116
LF 0117
LF 0153
LF 0111
0443
0444
HQ-111
HQ-130
HQ-144
HQ-132
HQ-131
HQ-135
HQ-136
HQ-137
HQ-133
HQ-134
HQ-138
HQ-140
LF 0154
LF 0130
LF 0155
LF 0144
LF 0132
LF 0131
LF 0135
LF 0136
LF 0137
LF 0133
LF 0134
LF 0138
LF 0140
0500
0493
0882A
0881
8080
8081
8078
0436
0884
0479
0885
Technical Manual- LIGHT VEHICLE - 19
Conversion Table – Brake Pads
FRAS-LE
LONAFLEX
PD/1
BENDIX
BOSCH
COBREQ
FMSI
HQ-2023
PB 23
N-103
7273 D384
20011
WVA
PD/5
P-5
HQ-2015
PB 15
N-201
755 D21
735 D30
20009
PD/6
P-6
HQ-2020
PB 20
N-302
7255 D31
20034
HQ-2010
PB 10
N-301
719 D2
20030
PD/7
PD/8
PD/10
P-10
PD/11
PD/13
P-13
PD/16
PD/60
P-60
PD/61
N-156
7626 D757
PB 95
N-829
HQ-2057
HQ-2106
PB 57
N-138
PB 150 A/2
N-534
PB 18
N-208
7021 D45
20011
PD/65
P-65
PB 16
N-207
7032 D96
20228
PD/66
P-66
7031 D96
20228
PD/66-A
20375
PD/66-B
PD/19-C
P-19-C
HQ-2012
PB 12
N-109
PD/22
P-22
HQ-2019
PB 19
N-309
7013A D50
7605 D736
PB 148
HQ-2016
N-501
N-348
HQ-2139
HQ-2018
PB 22
N-532
PB 96
HQ-2095A
N-304
HQ-2022
PB 146
HQ-2096
PD/64
PB 09
P-18
21829
HQ-2154
PD/63
HQ-2009
23484
8251 D1140
20753
N-539
21636
PB 150 A/1
PD/67-A
PD/68
HQ-2246
HQ-2066A
WVA
20961
N-146
N-108
PD/18
FMSI
7335 D340
PB 147
P-62
N-303
N-204
COBREQ
HQ-2103
PD/62
PB 11
PB 17
BOSCH
7625 D756
7625 D824
PB 01
HQ-2017
BENDIX
HQ-2168
HQ-2011
P-17
PD/22-B
LONAFLEX
PD/59
HQ-2001
PD/17
20578
FRAS-LE
HQ-2101A
PB 0155
N-700
23070
P-68
HQ-2062
PB 152
N-533
23229
23649
HQ-2028A
PB 19 A/1
N-310
PD/23
P-23
HQ-2008
PB 08
N-209
7242 D350
21193
PD/69
P-69
HQ-2129A
PB 153
N-1204
PD/24
P-24
HQ-2003
PB 03
N-115
7529 D649
20752
PD/71
P-71
HQ-2089A
PB 0237
N-835
20783
PD/72
P-72
HQ-2137
PB 0238
N-351
8252 D1141
23057
PD/73
P-73
HQ-2170
PB 0240
N-262
7635 D768
21974
HQ-2171A
PB 0240 A/1
N-263
HQ-2272
PB 279
N-1359
PD/68-B
PD/24-A
HQ-2167A
PB 03 A/2
N-117
7529 D649
PD/24-B
HQ-2002A
PB 03 A/1
N-116
7529 D649
HQ-2005
PB 05
N-503
7242 D350
PD/25-A
HQ-2007A
PB 05 A/2
N-506
PD/25-B
HQ-2006A
PB 05 A/1
N-504
PD/25
PD/26
P-25
P-26
PD/27-A
PD/28
P-28
PD/32
PD/74
P-74
PD/76
PB 14
N-505
PD/77
P-77
HQ-2172A
PB 0391
N-355
N-521
PD/78-A
P-78-A
HQ-2066A
PB 0078 A/2
N-534
HQ-2029
PB 29
N-214
HQ-2170
21193
PD/79
PB 107
29009
PD/80
HQ-3009PA
N-182
PB 108
20166
PD/81
P-81
HQ-3004PA
N-289
20660
PD/82
P-82
HQ-3001PA
N-358
HQ-2162A
PB 110
N-851
HQ-2046
PB 46
N-128
PD/35
P-35
HQ-2059
PB 41
N-144
PD/36
HQ-2055
PB 55
N-133
PD/37
HQ-2039
PB 39
7242 D350
7529 D649
HQ-3003PA
PD/84
HQ-3008PA
N-375
HQ-2279
N-598
23300
PD/85
7568 D693
21832
PD/87
HQ-3000PA
N-542
N-319
7666 D796
21190 /
21192 /
21201
PD/88
HQ-3010PA
N-595
P-85
PB 40
N-321
7614 D709
21050
PD/90
HQ-3007PA
HQ-2056
PB 56
N-131
7201 D298
20907
PD/91
HQ-3002PA
N-183
PD/40
HQ-2110
PB 140
N-322
21368
PD/92
HQ-3005PA
N-543
PD/41
HQ-2111
PB 139
N-326
7314 D426
21140
PD/93
HQ-2038
PB 38
N-324
7563 D688
20547 /
21353
PD/43
P-43
PD/44
P-44
PD/44-B
HQ-2037
PB 37
N-222
HQ-2042
PB 42
N-227
HQ-2042A
PB 42 A/1
N-228
PD/45
P-45
HQ-2045
PB 45
N-232
PD/46
P-46
HQ-2157A
PB 0235
N-360
PD/47
P-47
PD/47-A
PD/48
P-48
8290 D1176
HQ-2049
PB 32
N-511
21193
PB 32 A/2
N-513
21962
HQ-2081
PB 50
N-530
7201 D298
HQ-2050A
PB 50 A/2
N-516
PD/49
HQ-2114
PB 141
N-514
7144 D228
HQ-2030
PB 30
N-316
7489A D610
PD/51
P-51
HQ-2065
PB 142
N-235
8288 D350
PD/52
P-52
HQ-2132
PB 143
N-332
PD/54
P-54
HQ-2054
PB 54
N-239
8284 D1173
PD/55
P-55
HQ-2051
PB 51
N-136
8316 D1196
PD/57
P-57
HQ-2060A
PB 144
N-344
PD/58
P-58
HQ-2107
PB 145
N-252
PD/58-B
23226
HQ-2032A
PD/48-A
PD/50
HQ-2107A
PB 0145 A/1
N-254
PD/94
PD/102
20907 /
20908
20668
21202
23063
7860 D768
7709 D768
HQ-2025
PB 25
N-118
HQ-2004
PB 04
N-308
21974 /
23130
23187 /
23131
8321 D1201
PD/104
P-104
HQ-2026
PB 26
N-705
PD/105
P-105
HQ-2034
PB 34
N-317
PD/106
P-106
HQ-2036
PB 36
N-330
PD/107
P-107
HQ-2048
PB 48
N-327
HQ-2079
PB 79
N-708
PD/109
P-109
HQ-2025
PB 97
N-118
PD/110
P-110
HQ-2113
PD98
N-341
7593 D726
23663
PD/111
P-111
HQ-2191
PB 91
N-717
7848 D949
29153
HQ-2091A
PB 91 A/2
N-710
7848 D949A
29076
PB 101
N-335
PB 102
N-1324
PB 103
N-844
7298 D436
21679 /
21785/
21789 /
21790
PB 105
N-713
PD/108
PD/111-A
PD/113
P-113
PD/114
21862
8777 D1568
N-367
P-102
PD/103
23120
21636
PD/89
HQ-2040
P-42
8308 D1189
N-179
PD/39
PD/42
23487
7679 D806
PB 43 A/2
P-34
P-38
21195
HQ-2014
PD/34
PD/38
PD/73-B
HQ-2043A
PD/29
PD/31
21193
PD/115
P-115
HQ-2126A
P-117
HQ-2122
7968 D1062
29835
8328 D1208
29071
PD/116-F
PD/116-FK
PD/117
PD/117-A
29117
PB 105 A/1
PD/118
P-118
HQ-2121
PB 106
N-712
PD/122
P-122
HQ-2118
PB 100
N-557
7829 D928
23021
29121
Technical Manual- LIGHT VEHICLE - 20
Conversion Table – Brake Pads
FRAS-LE
LONAFLEX
BENDIX
BOSCH
COBREQ
FMSI
WVA
FRAS-LE
LONAFLEX
PD/379
PD/125-F
PD/129-F
PD/132
PB 0422
PD/134
PB 0392
PD/135
PB 0512
PD/139
HQ-2026
PD/189
HQ-2270
7353 D473
N-1415
21539
7744 D869
23951
PD/382
23318
PD/383
PD/190
BOSCH
COBREQ
FMSI
PB 125
N-1306
7331 D451
21333
7332 D452
21344 /
21345 /
21346
PD/380
7530A D650
N-1507
BENDIX
HQ-2143A
PB 126
P-383
HQ-4080A
PB 127
N-1201
7376 D497
21773
HQ-2131A
PB 128
N-1300
7412 D530
21363
29122
PD/384
HQ-2162
PB 0247
N-255
7434 D555
21911
29229
PD/384-A
HQ-2162A
PB 129 A/2
N-264
7434A D555
20676
29232
PD/385
HQ-2146
PB 0248
N-859
7437 D558
21292
PD/195
PD/386
PD/196-K19
PD/387
HQ-2105A
PB 131
PD/388
HQ-2151
PB 132
PD/389
HQ-2191
PB 133
PD/201
WVA
29231
PD/204
PB 130
PD/390
PD/300
HQ-4014A
N-737
PD/305-A
HQ-2078A
PB 0327 A/1
N-430
7194 D292
20937
PD/391-A
PD/312-A
HQ-2075A
PB 75 A/2
N-874
7116 D193
20632
20926 /
20928
PD/318-A
HQ-2076A
PB 76 A/1
N-433
PD/321-A
HQ-2072A
PB 72 A/2
N-427
7244 D351
21016
PD/322-A
HQ-2074A
PB 74 A/2
N-421
7261 D371
20905
7178 D273
21331
N-841
7441 D695
21601
N-1316
7448 D568
21879
7479 D601
26637
21388
PB 134
P-391-A
20753
HQ-2104A
PB 135 A/2
N-449
8255 D1145
PD/392
HQ-4011
PB 0403
N-1413
7438B D641
PD/397
HQ-2189A
PB 0288
PD/398
HQ-2281A
PD/403-B
HQ-2067A
7443 D564
PB 0249 A/1
PD/404
PB 0465
PD/405-E
PB 0290
PD/326-A
HQ-2077A
PB 77 A/2
N-881
7334 D454
21209 /
21210
PD/327
HQ-2102
PB 109
N-440
7394 D516
21096
PD/411
PD/410
P-411
HQ-2134
7345 D465
N-562
21497
21738
21927
21697
8342 D1221
21674
PB 0250
N-174
7545A D667
23627
PB 0251
N-1157
8309 D1190
23346
HQ-2052
PB 52
N-883
7209 D569
20887
PD/411-E
P-329
HQ-2084
PB 84
N-885
7570 D696A
20168
PD/412
HQ-2088
PB 88
N-892
20780
PD/412-B
PD/331
P-331
HQ-2082A
PB 111
N-888
23784
PD/414-E
PD/332
P-332
HQ-2058
PB 58
N-140
23472
PD/416
HQ-2080A
PB 80
N-886
20002 /
20191 /
20192
PD/417
HQ-2218
7144 D228
20668
PD/418
HQ-2152
PD/335-A
HQ-2115A
PB 114
N-518
D147
20833
PD/419
PD/336
HQ-2100
PB 115
N-896
7571 D684A
20168
PD/422
PB 255
PB 117
N-448
21404
PD/422-A
PB 117 A/2
N-443
21463
PD/423
PB 256
7350 D470
21495
PB 0242 A/2
N-575
29107
PD/424
PB 0296
7267 D378
21059
PD/328
PD/329
PD/330
PD/333
PD/334
PB 113
PD/338
P-338
HQ-2063
PD/338-A
P-338-A
HQ-2063A
PD/339-A
PD/340-B
PD/341
P-341
PD/343
7532 D652
8256 D1146
PB 156
N-1100
23124
HQ-2068
PB 138
N-1156
23205
HQ-2128A
HQ-2117A
PB 138 A/2
N-446
PB 157
N-1113
PB 252
N-867
7849 D950
23471
PB 253
N-731
7507A D477
7358A D477
21576 /
21577
PB 158
N-1400
7358 D712
21822
PB 0404
N-1331
7435 D556
21907
PB 255 A/2
21724
21799
N-555
21800
PB 0257
N-1327
7228 D333
21347 /
21348 /
21349
PD/429
HQ-2061
PB 0258
N-847
7205 D303
21158
PD/430
HQ-2123
PB 0259
N-824
23600
PD/431
BX-92
PB 0299
N-1200
23613
PD/432
HQ-4061
PB 0260
N-1303
7559 D680
23314
HQ-2187
PB 0405
N-1158
8254 D1143
23597
HQ-2153
PB 0406
N-363
7946 D1043
HQ-2160A
PB 0408-A
N-566
N-264
7710 D687
23392
PB 0396
N-727
7909 D1006
21592
HQ-2149A
PB 0397
23520
7257 D366
20008
PB 0398
HQ-2069A
HQ-2225
PB 0395
HQ-2219
PD/344
P-412
PD/427
P-427
21103
20939
PD/346
P-346
HQ-2206
PB 0400
PD/347
P-347
HQ-2275
PB 0401
N-450
PD/352
HQ-2064
PB 118
N-147
7528 D648
7528D745
21394
PD/352-A
HQ-2064A
PB 0118 A/2
N-149
7672 D801
21395
PD/353
HQ-2206
N-1168
PD/438-B
HQ-2215A
N-1238
PD/439
HQ-2141
PB 0261
N-559
21797
PD/441
HQ-2145
PB 0409
N-1312
7540 D660
21142
N-161
7690 D816
23154
PD/354
P-354
PD/358
PB 0245
PD/358-A
PD/362
P-362
PD/364-A
PD/365
PD/367
PD/368
PD/369-B
P-365
P-367
P-368
HQ-2116A
PB 0245 A/2
N-553
HQ-2085
PB 85
N-884
HQ-2135A
PB 0246 A/2
N-897
HQ-2202A
N-189
HQ-2102
N-260
N-820
PB 120
HQ-2108
HQ-2109
PB 0149
N-810
HQ-2159A
PB 0402-A
N-565
PD/374
PB 121
PD/376
7234 D340
7569 D694
C/16mm
PB 122
PD/437
PB 0407
P-438-B
21798
PD/442
HQ-2136
PB 0262
PD/449
HQ-2265A
PB 0305
21430
PD/450
HQ-4045A
PB 0264
PD/453
HQ-2149
PB 0308
21866
21866
23602
7125A D387
P-435
PD/436
20961
7709 D833
7569 D694
PD/435
21830
7219 D466
21654
PD/377
HQ-2124A
PB 123
N-826
7241 D349
21373
PD/378
HQ-2144A
PB 124
N-1309
7305 D418
21500
P-442
7951 D1048
23603
23177
7382 D503
21651
N-1340
7447 D567
21840
N-1211
7342 D462
21527
PD/458-B
PB 0312 A/1
7401 D520
21897
PD/464-B
PB 0314 A/1
7398 D518
PD/465
P-465
HQ-2176A
PB 265
N-1104
21237
20974
PD/469
PB 266
7365 D484
21647
PD/470
PB 0318
23242 /
23243 /
23244
PD/471-A
PB 0319 A/2
23230 /
23231 /
23232 /
23233
Technical Manual- LIGHT VEHICLE - 21
Conversion Table – Brake Pads
FRAS-LE
LONAFLEX
BENDIX
BOSCH
COBREQ
FMSI
WVA
FRAS-LE
PD/551
LONAFLEX
BENDIX
BOSCH
COBREQ
FMSI
PB 267
N-893
8247 D1137
23081 /
23082 /
23083
PB 0560
N-1372
7155 D275
PD/474
PB 268
N-832
7551 D671
21519
PD/556
PB 0561
N-1409
7502A D666
PD/475
PB 0321
N-1223
PD/478
PB 0323
PD/473
HQ-2127A
PD/480
HQ-2175
PD/482
PB 269
N-163
23234
PD/560
PB 0562
7543 D664
23238 /
23239 /
23240
PD/561
PB 0563
7566 D691
PD/562
PB 0564
7566 D855
7763 D886
23353
PD/565
HQ-2190A
PB 0565
7576 D702
21964
PD/566
HQ-2199
PB 0566
7584 D711
21147
PD/571
PB 0567
7652 D784
21383
PD/572
PB 0568
PD/573
PB 0569
23442
PD/575
PB 0570
21635
PD/580
PB 0571
PD/581
PD/582
HQ-2119A
PB 270 A/2
N-605
PD/484-A
HQ-2120A
PB 271 A/2
N-607
PD/485
HQ-2125
PB 272
N-833
7616 D746
PD/486
HQ-2130A
PB 273
N-1207
7641 D774
PD/487
HQ-2140
PB 274
N-258
PD/488
HQ-2148
PB 275
PD/489
HQ-4040
PB 276
HQ-2174
PB 0410
PD/492
HQ-2211
PB 0411
PD/493
HQ-2150A
PB 0412
PD/491
7469 D590
7567 D692
21607
7523 D645
21439
PB 277
P-491
20162
N-1319
23766
7518A D642
N-1313
7497 D621
21694
PB 350
PD/585
PD/494
P-494
23842
PD/586
PD/497
P-497
HQ-2173
PB 0413
N-152
8289 D1175
23202
PD/588
PD/498-A
P-498-A
HQ-2233A
PB 0414-A/2
N-573
8318 D1198
23917
PD/592-B
PD/500
P-500
HQ-2222
PB 0415
N-1337
23879 /
23880
PD/501
P-501
HQ-2234
PB 0416
N-1169
23921
PD/502
PD/503
PD/505
7259 D369
P-503
P-505
HQ-2161A
HQ-2226
PD/507
PD/509-B
P-509-B
HQ-2179A
PD/510
N-1344
HQ-2178A
P-512
N-1166
PB 0515
N-1165
23332
N-569
23705 /
23706 /
23707
PB 0516
PB 0418
PB 0419-A/4
PD/525-A
HQ-2253A
PB 0420-A/2
7863 D981
PB 0576 A/1
7921 D1018
23882
7790 D911
23557
N-583
PB 0577
PB 0578
PD/611
PB 0579
7557 D677
23400
PB 0580
7587 D716
23032
HQ-2201
PB 0581
N-1335
7589 D721
23558 /
21915
HQ-4065
PB 0582
N-1336
7590 D722
23780
PD/616
HQ-4046A
PB 0583
0986424711
7602 D733
23593
PD/619
HQ-4053A
PB 0584
7637 D770
23572
23631 /
23336
PD/613
PD/614
N-1220
7660 D790
PB 0586
N-1160
7616 D820
7738 D862
23585
N-1451
7955 D1051
23656
HQ-4093A
PB 0589
N-1250
7739 D864
23569
PD/631
HQ-4042
PB 0590
N-1446
7741 D866
23584
N-1153
21460
PD/632
HQ-2221
PB 0591
7743 D868
23582
N-1147
20906
PD/633
PB 0592
PD/634
PB 0593
N-1241
PB 0594
N-1231
7825 D924
N-1444
7864 D965
PB 0426
29115 /
29116
P-527
HQ-2204A
PB 0421
N-1360
7671 D799
PD/528
P-528
HQ-2227A
PB 0427
N-1449
7877 D976
24024 /
24025 /
24026
PD/529-F
PD/531
HQ-2251A
PB 0519
N-1425
7716 D841
PD/532
HQ-2090A
PB 0554
N-1178
7389 D510
HQ-2238
PB 0384
HQ-2224A
PB 0555
7876 D830
PB 0556
8253 D1142
21657
29148 /
29115
PB 0557
7703 D830
N-1343
7742 D867
7070C D183
PD/635
HQ -2216A
PD/637
HQ-2197A
21561
24092
24178
24179
23891
23892
23893
/
/
/
/
PB 0595
7870 D969
24056
PD/644
PB 0596
7795 D914
23868 /
23869
7418 D1086
24231 /
24332 /
24333
PD/645
HQ-2248A
PB 0597
PD/646
HQ-2213
PB 0598
N-186
8272 D1161
PD/647
HQ-2212
PB 0599
N-185
8277 D1164
HQ-2232
PB 0600
N-1171
23406 /
23407
HQ-2210A
PB 0601 A/4
N-1174
23277
PD/649-E
24066
24275
PD/638
PD/648
7260 D370
PB 0559
HQ-2252
PB 0585
PD/630
21938
/
/
23930
23714
7715 D840
/
/
23279
23581
PB 0518
PB 0558
24036
24037
24038
23814
23871
23872
PD/601
PD/620
PD/527
PD/550
7789 D910
PB 0575
N-1441
PD/599
23708 /
23709 /
23710
21775 /
21776
HQ-2192-A
PB 0574
HQ-2249
PB 0588
HQ-2163A
PD/548
7784 D905
PD/629
HQ-2184A
HQ-2220
986494090
23669
PD/522-E
PD/538
HQ-4060A
PB 0587
PD/521-E
PD/536
7734 D858
PD/628
HQ-2155
PD/535
PB 0573
PD/623
HQ-2180
PD/534
23640 /
23642
23816
PD/520
P-533
7733 D857
23409
PD/518
PD/533
PB 0572
N-1334
8325 D1205
23339
23635
N-1164
HQ-2274
7661 D791
23638
PB 0425
PD/516
7653 D785
N-1418
7732 D856
N-582
HQ-2181
23420
7674 D803
PB 0517 A/1
HQ-2177
HQ-2217
7623 D730
20449
PD/598
PD/612
PB 0424
PD/514
PD/526
8320 D1200
23599 /
23954
PB 0553
PD/511-B
PD/512
PB 0417
HQ-2214A
7667 D797
PD/483-A
PD/490
P-554
8258 D1148
PB 0423
N-723
PD/554
WVA
7339 D459
P-648
PD/650-E
PB 0602 A/4
PD/651
PB 0603
23273
N-1170
23305
Technical Manual- LIGHT VEHICLE - 22
Conversion Table – Brake Pads
FRAS-LE
PD/652-B
LONAFLEX
P-652-B
BENDIX
HQ-2260A
BOSCH
PB 0604 A/1
COBREQ
FMSI
WVA
23919 /
23920
N-596
FRAS-LE
PD/1072
PD/662
PD/1077
PD/663
PD/1078
PD/665
N-1242
7979 D1074
PD/666
N-1249
7344 D464
21553
7917 D1013
24068
24069
24070
23725
23726
23727
23728
PD/667
PD/668
PD/669
N-903
P-669
PD/672
HQ-2229A
N-1366
HQ-2247A
N-1277
PD/680
PD/681
PD/685
P-685
HQ-2207A
HQ-2245A
PD/689
P-689
HQ-2228A
N-1377
N-1368
PD/692
8379 D1261
/
/
/
/
/
/
23993
7939 D1036
24071
HQ-4044
N-1449
PD/696
7487 D606
7489 D610
PD/708
HQ-2264A
HQ-4007A
PD/711
PD/715
N-1400
7358 D477
N-371
8381 D1264
N-372
PD/717
HQ-2189A
PD/725
HQ-2267A
HQ-4021A
8391 D1275
24510
24511
24512
24498
24499
24500
PD/728
7688 D813
23543
7783 D815
8307 D1188
HQ-2277
HQ-4050
8377 D1258
24544
PD/1081
HQ-2250
HQ-4017
N-1466
8378 D1259
24545
N-1247
8505 D1397
HQ-4023
N-1259
8267 D1157
HQ-2287A
N-1447
PD/1092
PD/1093
8689 D1489
PD/1100
HQ-2158
N-288
8768 D1556
PD/1101
HQ-4070A
N-384
8730 D1522
PD/1102
HQ-4071A
N-387
8668 D1468
24375 /
24376
PD/1287
HQ-2269A
HQ-4024A
N-1243
8322 D1202
24351 /
24352 /
24568 /
24569
N-1256
8614 D1295
24501
PD/1296
PD/1298
HQ-4080A
8417 D1301
PD/1299
HQ-4081A
8418 D1302
PD/1303
8427 D1309
PD/1320
8463 D1354
23662
PD/1347
N-378
PD/758
7868 D966
HQ-2271A
N-1382
PD/775
24529 /
24530
N-187
HQ-2266A
8655 D1455
PD/1355
8370 D1252
PD/1356
8428 D1445
24557 /
24558
PD/1357
8698 D1498
PD/1358
8455 D1344
23587 /
23588 /
23589
PD/1364
8801 D1590
PD/1365
8804 D1592
PD/1366
8575 D1439
PD/811
8212 D1107
PD/1026
HQ-4013A
N-735
8439 D1327
PD/1028
HQ-2261
PD/1028-B
HQ-2261A
PD/1029-A
HQ-2262A
PD/1030
HQ-2209
8767 D1555
24484
N-292
8595 D1444
PD/1354
24342
N-279
HQ-4078A
8751 D1543
8402 D1285
7994 D1089
HQ-2208A
PD/1351
N-1272
PD/1353
23482
PD/1000-B
HQ-4029A
HQ-4076A
8400 D1202
7957 D973
PD/1000
PD/1348
23974 /
25295 /
25296
PD/1352
7863 D964
PD/796
8701 D1502
24486
8213 D1108
23914
/
/
8306 D1125
23928
P-771
/
/
N-192
7787 D908
23723 /
23724
25034
25035
25036
25096
25097
25098
N-1253
PD/745
7947 D1044
24468 /
24469
HQ-2235
N-286
N-190
/
/
HQ-2268A
PD/1346
HQ-3011PA
/
/
PD/1277
24336
PD/767
23966
23987
23988
24320
24321
24322
PD/1103
8330 D1210
N-1468
24346
8331 D1293
PD/1330
PD/740
PD/809
7702 D829
N-1467
/
/
PD/733
PD/771
WVA
23178 /
23179
HQ-2254
HQ-4016
/
/
7632 D764
N-1233
FMSI
8206 D1100
HQ-4059
PD/1099-B
7533 D540
PD/695
COBREQ
PD/1080
PD/1098
20870
BOSCH
PD/1097
8456 D1345
7153 D242
BENDIX
PD/1052
PD/661
PD/664
LONAFLEX
PD/1367
PD/1368
8428 D1594
23583 /
23584
25268 /
25629 /
25270
25153
25154
25155
25337
25338
25339
/
/
/
/
Proving Grounds
Headquarters - Main Manufacturing Facility - Caxias do Sul - RS - Brazil
Alabama Manufacturing Facility - United States
Stattes
Pinghu Ma
Manufacturing Facility - China
Manufacturing Facilities
Customers
03/2014
International Operations
FRAS-LE ARGENTINA
Calle 109 (ex 1º de Agosto), 2755
B1650NHF - San Martín
Provincia de Buenos Aires - Argentina
Tel.: (+ 54 11) 4752 8500
Fax: (+ 54 11) 4754 0911
[email protected]
FRAS-LE NORTH AMERICA INC.
103 Echlin Boulevard
Prattville, Alabama
36067 - USA
Tel: 1 (334) 358 5775
Fax: 1 (334) 358 5776
[email protected]
FRAS-LE ANDINA
Calle Andrés de Fuenzalida, 69
Oficina 701
Providencia – Santiago - Chile
Tel: (+ 56 2) 334 9349
Fax: (+ 56 2) 231 6281
[email protected]
FRAS-LE EUROPE
Ludwig-Erhard-Straße 8
45891 Gelsenkirchen
Germany
Tel: (+ 49 209) 386 240
Fax: (+ 49 209) 386 2415
[email protected]
FRAS-LE MÉXICO
Av. Universidad no. 989, Primer piso,
Oficina 103
Col. Del Valle - Delegación Benito Juárez
03100- México, D.F. – México
Tel: (+ 52 55) 5524 1896
Fax: (+ 52 55) 5524 1899
[email protected]
FRAS-LE ASIA
Pinghu Manufacturing Facility
No.1688 Hongjian Road,
Pinghu Economic Development Zone
Zhejiang Prov.
Postal Code 314200
P.R. China
Tel.: (+ 86 573) 8529 0700
Fax: (+ 86 573) 8529 0720
[email protected]
FRAS-LE AFRICA
Regent Hill office Park, Block C, Office 7A
Cnr Leslie & Turley Rds, Lonehill, 2062
Johannesburg - South Africa
Tel.: (+ 27 11) 702 8340
Fax : (+ 27 11) 467 1476
[email protected]
FRAS-LE MIDDLE EAST
P.O. Box 261416 Lob 13, 1st Floor, No. 28
Jebel Ali Free Zone Dubai - U.A.E.
Tel.: (+971) 4 8810344
Fax: (+971) 4 8810355
[email protected]
FRAS-LE S.A. - Matriz
RS 122 - Km 66, nº 10945 t Forqueta t 95115-550
Caxias do Sul t RS t Brasil
Tel.: (+55 54) 3239 1000 - Fax: (+55 54) 3239 1921
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