Technicians frequently pose questions on inspection procedures as they relate to service brakes, parking brakes, brake line repairs, rusted brake rotors, and inspecting wheel cylinders for leaks.

PennDOT regulations provide the following guidelines:

·                Passenger Cars and Light Trucks - Inspect the braking system. Remove at least one front and one opposite rear wheel.

·                Medium and Heavy Truck and Buses - Inspect the braking system. At least one front and one opposite rear wheel shall be removed. It is not necessary to remove the wheel and drum assembly if there is a removable backing plate that allows examination of the brake system.

·                Recreational, Semi-and Utility Trailers - Inspect braking system.

·                Motorcycles - Check the brake system by doing visual inspection. If the vehicle is equipped with view ports or mechanical brake wear indicators, wheels do not have to be pulled but the mechanic shall determine if lining should be replaced.

Frequently Asked Questions

Is an inspection mechanic required to remove brake pads from the caliper when performing a safety inspection on a passenger car, light or medium truck?

Yes. In order to properly inspect a vehicle’s braking system according to the inspection procedure, technicians must remove the brake pads from the caliper in order to:

1.       verify that the brake lining is being measured at the thinnest point or above the (highest set) rivet head; and

2.       verify that the lining is not cracked, broken or loose.

It is recommended but not required that the one front and one opposite rear wheel that is pulled be different from those pulled during the last inspection, as determined from the old safety sticker or station records.

Would a passenger car pass Safety Inspection with 2/32 bonded brake pads?

Yes. Minimum brake shoe or pad requirements are 1/32 riveted and 2/32 bonded – measured at the thinnest point.

Are cracked brake hoses rejectable for safety inspection?

Yes. Hydraulic hoses that have cracks or breaks to the extent that cords are visible are rejectable. Hoses that are insecurely fastened or improperly retained are likewise rejectable.

Is copper tubing acceptable for brake lines?

No. Only lines approved as brake lines shall be used as brake lines. Copper tubing is not an approved brake line.

May brake lines be repaired with compression fittings?

No. Compression fittings are designed for copper tubing not steele. To repair brake lines, technicians can use “Flareless Ermeto Fittings” (pictured below) for high pressure hydraulic applications up to 10,000 psi, depending on tubing size, are available. With this type of product, tube flaring is not required. Although this product is available, inverted flare unions with flare tube nuts are still the most effective way, both time-tested and mechanically sound, to repair brake lines. Double tube flaring is required for inverted flare unions.

Are technicians required to remove the rear disc brake rotor in order to inspect the parking brake lining?

In some cases, rear rotor removal to check the lining on a parking brake would require additional work that would be difficult to justify in the normal course of a Safety Inspection. It would be prudent for the technician to check the parking brake operation during the road test and if not satisfactory, additional work would be required with the owners permission.

A parking brake system shall be adequate to hold the vehicle on a surface free from ice or snow on a 20% grade with the vehicle in neutral.

Check the parking brake operation and REJECT IF the pedal or lever reaches its limit of travel before parking brakes are set.

In addition, a technician would REJECT IF:

Are brakes required on all truck and trailers axles?

Yes. All axles, including lift or tag axles on trucks, are required to be equipped with brakes. Trailers greater than 3,000 GVWR are required to have brakes on all axles.

Is it necessary to check brake wheel cylinders for leakage behind the dust covers?

No. On some applications it is difficult to check behind the dust cover without damage. In addition, brake fluid bypassing the cylinder cup will leak past the dust cover leaving an indication on the backing plate.

Is a rust pitted brake rotor rejectable?

Yes. Technicians should REJECT IF the drums or rotors are scored deeper than .015 inches. Also, technicians should REJECT IF there is mechanical damage other than wear. In most cases rusted rotors indicate a deterioration of the metal and are deeper than .015 inch. The rotor has the potential for massive destruction during severe brake application.

What are service brake requirements for passenger cars during a road test?

Technicians should REJECT IF the vehicle is not capable of stopping within the maximum distance. Passenger cars need to stop within 20 feet at 20 MPH without swerving out of a normal 12 foot driving lane.

Will a pulsating brake pedal, indicating a warped rotor, fail a road test for Safety Inspection?

It depends. There are degrees of pulsation that need to be determined for purposes of a road test rejection. A slight pulsation of a brake pedal or slight vibration of the vehicle during normal brake application would most likely indicate slight rotor run-out. A vehicle would not fail the road test for Safety Inspection based on the slight pulsation alone. Heavy pedal pulsation would indicate much more rotor run-out which could cause brake pads to float on a severe brake application resulting in a loss of braking ability. A vehicle would fail safety inspection for heavy pedal pulsation.