2005 Chevrolet Cavalier Brake Service (ONLINE REPAIR MANUALS)

Front & Rear Split System

When the brake pedal is depressed, both the primary (front brake) and the secondary (rear brake) master cylinder pistons are moved simultaneously to exert hydraulic fluid pressure on their respective systems.

If the rear brake system fails, initial brake pedal movement will cause the unrestricted secondary piston to bottom in the master cylinder bore. Primary piston movement will displace hydraulic fluid in the primary section of the master cylinder to actuate the front brake system.

If the front brake system fails, initial brake pedal movement will cause the ...

AC-Delco Tandem Diaphragm Type

This unit utilizes a vacuum power chamber, consisting of a front and rear shell, housing divider, front and rear diaphragm, plate assemblies, hydraulic pushrod and a diaphragm return spring, Fig. .

In normal operating mode, with service brakes in released position, the booster operates with vacuum on both sides of its diaphragms. When brakes are applied, air at atmospheric pressure is admitted to one side of each diaphragm to provide power assist. When the service brake is released, atmospheric air is shut off f...

These brakes have self-adjusting shoe mechanisms that ensure proper lining-to-drum clearances at all times. The automatic adjusters operate only when the brakes are applied as the vehicle is moving rearward.

An initial adjustment is required after the brake shoes have been relined or replaced, or when the length of the adjusting screw has been changed during service operations.

Frequent usage of an automatic transmission forward range to halt reverse vehicle motion may prevent the automatic adjusters from functioning, thereby inducing low pedal heights. Should low pedal heights be enc...

Two basic types of power assist mechanisms are used: vacuum assist diaphragm assemblies, which use engine vacuum or, in some cases vacuum pressure developed by an external vacuum pump. The second type is a hydraulic pressure assist mechanism, which use pressure developed by an external pump (usually the power steering pump). Both systems act to increase the force exerted on the master cylinder piston by the operator. This in turn increases the hydraulic pressure delivered to the wheel cylinders while decreasing driver effort required to obtain acceptable stopping performance.

Vac...

When working on or around brake assemblies, care must be taken to prevent breathing asbestos dust, as many manufacturers incorporate asbestos fibers in the production of brake linings. During routine service operations the amount of asbestos dust from brake lining wear is at a low level because of a chemical breakdown during use and a few precautions will minimize exposure.

• Do not sand or grind brake linings unless suitable local exhaust ventilation equipment is used to prevent excessive asbestos exposure.
• Wear suitable respirator approved for asbestos dust use during repair procedure...

Removal

• Raise and support rear of vehicle, then remove tire and wheel assembly.
• Mark drum and axle hub, then remove brake drum. If brake lining is dragging on brake drum, back off brake adjustment by rotating adjustment screw. If brake drum is rusted or corroded to axle flange and cannot be removed, lightly tap axle flange to drum mounting surface with suitable hammer.
• Unhook primary and secondary return springs using brake spring removal and installation tool Nos. J-8049 or J-29840, or equivalents, Fig. . Observe location of brake components being removed to aid during installation.
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