Failure Analysis
Failure Analysis
Inspecting components to determine
the cause for failure
Object is not repaired until the cause
for failure has been determined
Fade - Performance
Problems
Uneven Wear - Brake Shoe
Broken webs on relined shoes
Common overload failure mode on garbage trucks
Broken webs on shoe
Shock load failure caused by repeated extreme brake applications.
MISSING LINING ON CAM SIDE OF SHOE
Shock load failure caused by repeated
extreme brake applications. Seen on severe
duty applications.
Could not get drum over brakes.
Aftermarket material not to OEM specs.
Lining chunking
Caused by abuse and overheating. Look for signs of
heat on other components.
Rust Jacking
• Formation of an oxide
layer developed and
growing on the brake shoe
table.
• Oxide layer is created by a
corrosive action.
• Formation of the ferrous
oxide layer causes brake
block to be pushed away
from brake shoe table.
Causes of Rust Jacking
• Geographic region of operation
• Container chassis trailers
– Parked at sea ports
• Change in de-icing compounds
– Magnesium Chloride
– Calcium Chloride
– Sodium Chloride (Salt)
• Time and brake usage
– Oxidation process takes time to develop
– Block life correlates to operational duty cycle
How to Detect Lining Block Rust Jacking
• Visual inspection with
wheels on
– Look for radial cracks in
the edge of block.
• Visual inspection with
wheels off
– Look for cracks across
block face.
• Listen for brake noise
Grooved Brake Lining Wear -
Abrasive materials inside of drum such as small stones
Tapered Brake Lining Wear
Not Worn
Worn
BENT SPIDER OR WORN CAM BUSHINGS
Tapered Lining Wear
•Drum may be bell mouthed
•Inspect drum inner diameter
•Worn cam rollers
•Worn anchor pins
•Broken or weak hold down springs
Cracked lining
Rust Jacking
CRACKED LINING
This is called:
De-lamination.
Manufacture defect
Cracked lining
Block not tightly fastened – loose rivets
Hot spots in brake drum
Out of round drums may look the same in appearance but are usually caused
by improper fit-up to wheel hub or heat distortion.
Heat checked brake drum
HEAT CHECKED DRUMS
Second stage of heat spot formation.
Spot continues to grow in size
Caused By:
• Constant heating and cooling and brakes
• Brake imbalance
• Dragging brakes
• Driver abuse
• Not need to replace most of the time
Cracked drum
Final result of hot spot formation is drum failure.
CRACKED DRUM
Final result of hot spot formation is failure of the
drum
Caused By:
•Dropped drum
•Improper shoe contact
•Fatigue due to heating
Corrections
•Replace brake drum
•Check brake balance and operation
Grooves in brake drum
Abrasive material between drum and lining.
Performance Analysis - Camshaft
Lack of lube
Performance Analysis - Spider Assembly
Chamber bracket bolts were loose.
Performance Analysis - Bracket Assembly
Chamber bracket bolts were loose.
Performance Analysis - Spring Brake Chamber
Broken stud.
Performance Analysis – Bracket Assembly
Bracket failure at
chamber end with
external support.
Performance Analysis – Bracket Assembly
Bent bracket
above the gusset.
Brake shoe overhanging
Excessive end play.
Performance Analysis – Return Spring
Wheel lock up due to a broken hold down spring.
Broken shoe retainer clip
Performance Analysis – Tone Ring
Shoe clip broke and caused damage to ABS tone ring