By the end of this chapter, you will be able to:
Mastering these skills ensures vehicles operate safely and efficiently, helping you become a trusted professional in motor vehicle maintenance.
Type: Individual
| Tools & Equipment | Materials |
|---|---|
| Complete tool box including spanners, screwdrivers, pliers, and brake adjusting tools | Brake fluid |
| Hydraulic jack and safety stands | Cleaning cotton waste |
| Measuring ruler or vernier caliper | Personal protective equipment (overall, gloves, safety boots, goggles) |
| Brake pedal free play gauge or ruler marked in millimeters | |
| Wheel chocks |
| S/N | Item | Quantity |
|---|---|---|
| 1 | Complete tool box including spanners, screwdrivers, pliers, and brake adjusting tools | 1 set per Candidate |
| 2 | Service manual for the specific vehicle make and model | 1 copy per Candidate |
| 3 | Personal protective equipment (overall, gloves, safety boots, goggles) | 1 set per Candidate |
| 4 | Wheel chocks | 2 pcs per Candidate |
| 5 | Brake fluid | Sufficient per Candidate |
| 6 | Cleaning cotton waste | Sufficient per Candidate |
| 7 | Hydraulic jack and safety stands | 1 set per Candidate |
| 8 | Measuring ruler or vernier caliper | 1 per Candidate |
| 9 | Brake pedal free play gauge or ruler marked in millimeters | 1 per Candidate |
| 10 | Live light-duty vehicle with adjustable brake pedal | 1 per Candidate |
| Items to be Evaluated | Marks Available | Marks Obtained | Comments |
|---|---|---|---|
| TASK 1: Adjust Brake Pedal Free Play | |||
| Wore personal protective equipment (overall, gloves, safety boots, goggles) (Award 1 mark for each PPE worn or zero) | 4 | ||
| Parked vehicle on a flat surface and chocked the wheels (Award 2 marks or zero) | 2 | ||
| Loosened the brake pedal lock nut or adjuster lock as per service manual (Award 2 marks or zero) | 2 | ||
| Measured the initial brake pedal free play using brake pedal free play gauge or ruler (Award 3 marks or zero) | 3 | ||
| Adjusted the brake pedal free play to between 10 mm and 15 mm as per manufacturer specifications (Award 5 marks only if free play is within specified range) | 5 | ||
| Tightened the brake pedal lock nut or adjuster lock securely after adjustment (Award 2 marks or zero) | 2 | ||
| Checked brake fluid level in the master cylinder reservoir and topped up if necessary (Award 3 marks or zero) | 3 | ||
| Cleaned any spillage around the brake fluid reservoir using cotton waste (Award 1 mark or zero) | 1 | ||
| Tested brake pedal for correct operation and free play after adjustment (Award 3 marks or zero) | 3 | ||
| Lowered vehicle safely after inspection and adjustment (Award 2 marks or zero) | 2 | ||
| Sub-Total | 27 | ||
| PRODUCT CHECKLIST | |||
| Brake pedal free play adjusted accurately between 10 mm and 15 mm (Award 5 marks only if measurement is within specified range) | 5 | ||
| Brake pedal operates smoothly without binding or excessive play (Award 3 marks or zero) | 3 | ||
| No brake fluid leakage or spillage around master cylinder and reservoir (Award 3 marks or zero) | 3 | ||
| Sub-Total | 11 | ||
| GRAND TOTAL | 38 | ||
Type: Individual
| Tools & Equipment | Materials |
|---|---|
| Clutch pedal free play measuring ruler or gauge | Cleaning cotton waste |
| Spanner set | Personal protective equipment (Overall, Gloves, Safety boots, Goggles) |
| Screwdriver set | |
| Service manual |
| S/N | Item | Quantity |
|---|---|---|
| 1 | Vehicle with manual transmission | 1 Pc per Candidate |
| 2 | Clutch pedal free play measuring ruler or gauge | 1 Pc per Candidate |
| 3 | Spanner set (including 10mm and 12mm spanners) | 1 Set per Candidate |
| 4 | Screwdriver set | 1 Set per Candidate |
| 5 | Service manual for the vehicle | 1 Copy per Candidate |
| 6 | Cleaning cotton waste | Sufficient per Candidate |
| 7 | Personal protective equipment (Overall, Gloves, Safety boots, Goggles) | 1 Set per Candidate |
| Items to be Evaluated | Marks Available | Marks Obtained | Comments |
|---|---|---|---|
| TASK 1: Adjust Clutch Pedal Free Play | |||
| Wore personal protective equipment (Overall, Gloves, Safety boots, Goggles) (Award 1 mark for each or zero x 4 = 4 Marks) | 4 | ||
| Parked vehicle on flat surface and applied handbrake, chocked wheels (Award 2 marks or zero) | 2 | ||
| Opened vehicle hood to access clutch linkage (Award 1 mark or zero) | 1 | ||
| Cleaned clutch pedal and linkage area using cotton waste (Award 1 mark or zero) | 1 | ||
| Measured initial clutch pedal free play using ruler/gauge (Award 1 mark for correct tool use, 1 mark for accurate measurement, 1 mark for recording result) | 3 | ||
| Loosened lock nut on clutch cable or linkage (Award 2 marks or zero) | 2 | ||
| Adjusted clutch pedal free play to between 10 mm and 20 mm as per service manual (Award 4 marks or zero) | 4 | ||
| Tightened lock nut securely after adjustment (Award 2 marks or zero) | 2 | ||
| Re-measured clutch pedal free play to confirm adjustment (Award 1 mark for correct tool use, 1 mark for accurate measurement, 1 mark for recording result) | 3 | ||
| Tested clutch pedal operation for smoothness and proper engagement (Award 3 marks or zero) | 3 | ||
| Closed vehicle hood and cleaned work area (Award 1 mark or zero) | 1 | ||
| Sub-Total | 26 | ||
| PRODUCT CHECKLIST | |||
| Clutch pedal free play adjusted to between 10 mm and 20 mm as per specifications (Award 10 marks for correct final measurement or zero) | 10 | ||
| Sub-Total | 10 | ||
| GRAND TOTAL | 36 | ||
At the start of this chapter we promised you would be able to:
Tick each one you can genuinely do.
So, are you there yet?
You're competent when you can confidently do 50% or more of what this chapter promised.
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