Chassis Information --- Section 10
Cayman 2005
327
BRAKE SYSTEM
The chassis incorporates four separate braking systems: Service Brakes, Parking/Emergency, Antilock
Braking System (ABS) and the Engine (Exhaust). The Service Brakes Brake System uses a hydraulic
brake actuation system. This system includes a hydraulic booster assembly, a master cylinder assembly and a
monitoring system. A reserve electric-hydraulic pump is included as a safety feature to provide limited
power assist should the primary system fail.
The Hydro-Max brake system gets primary power for the booster from the power steering pump. The
reserve electric motor pump is turned on by a relay that is activated when an integral flow switch detects
the lost flow of power steering fluid. The brakes will remain operational with a greatly increased
stopping distance in the event that both the primary hydraulic and the backup electrical pump fail to
operate.
Electrical Pump & Master Cylinder
The electric pump motor provides reserve power
for the booster assembly. The entire assembly should
be replaced when a failure occurs. When the electric
pump motor is working you will only have one-half
the brake boost. Caution should be taken, as braking
distance will be increased. To test reserve power,
apply the brake pedal with the ignition "OFF." The
electric pump should run and be audible.
The design of the master cylinder provides two sepa-
rate brake fluid systems (front and rear). One system
will operate should a failure occur in the other. When
checking the fluid level in the master cylinder, the
fluid should be clean with no evidence of contamina-
tion. A surge of fluid should occur when the brake
pedal is applied, and fluid level should be at the
bottom of the port ring openings. Since the master
cylinder is the highest point of the system, gravity
flow bleeding can be accomplished. Gravity flow
bleeding requires only one person and NO pressure
bleeder. Each caliper has a bleeder valve for remov-
ing any air in the system.
090396
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