New UICS Brake Fluid Standard Guides Service And Replacement

MAINTENANCENew UICS Brake Fluid Standard Guides Service And Replacement

TUCSON, AZ (Sept. 15, 2005) - Since the day Henry Ford rolled out the first Model T, there has never been a standard in the United States for testing and replacing vehicular brake fluid. Brake fluid does not last forever, yet in today's age of regulation and standards, this important fluid has never had a recommended standard or service interval. Part of the problem was a lack of research into brake fluid's behavior over time, and part lay in the lack of reliable technology to monitor the condition of brake fluid.

Automakers and brake fluid manufacturers have long understood that exposing the various metal parts of a brake system to hydraulic fluid causes internal corrosion to occur over time. That is why brake fluid makers incorporate anti-corrosion compounds into their formulations. But what happens when the corrosion inhibitors are depleted? And how can professional technicians determine when depletion is close to occurring before it impacts their customer?

With the development of Antilock Braking Systems (ABS), what was once considered a non-issue has turned into a real concern. In response to vehicle owner complaints about the operation and performance of ABS, the National Highway Transportation Safety Administration (NHTSA) began examining components from ABS systems in the late 1990s at its Vehicle Research and Test Center in East Liberty, OH.

NHTSA found what appeared to be corrosion deposits in the ABS hydraulic pressure control valves as seen in Figure 1, and the Agency suspected that these observations were the result of corrosion of metallic components in brake fluid. In addition, NHTSA thought that ABS systems, with their increased circulation and closer tolerance valves, might be more susceptible to corrosion than conventional braking systems.

Figure 1. Corroded control valve.
(Photo: Phoenix Systems)

NHTSA requested that several groups, including the Society of Automotive Engineers (SAE) and the National Institute for Standards and Technology (NIST), conduct preliminary studies into the nature and scope of metallic corrosion in this environment. The objective of this work was to develop a better understanding of the corrosion phenomena in the ABS environment. In 1998, NIST released its report titled "Preliminary Investigations Into Corrosion in Anti-Lock Braking Systems."

This study was the genesis for a new technology to monitor brake fluid condition, which was developed and patented by Phoenix Systems, Tucson, AZ. Known as the FASCAR - short for "Fluid Analysis by Stimulation of Copper Alpha Reactions" - the system utilizes a color change technology that responds proportionately to the presence of copper ions in brake fluid. Using copper in brake fluid as a key predictor of corrosion, Phoenix Systems found a way to quickly and visually determine the overall condition of brake fluid as a means of predicting when internal brake system corrosion may occur and therefore when brake fluid should be replaced.

Similar to testing pool water for pH levels using litmus paper, the FASCAR Rating System uses a test strip and a color scale indicating the amount of copper present in brake fluid from zero to 300 parts per million (ppm). Within about 60 seconds, the white reaction pad of a FASCAR test strip will change to varying shades of purple depending on the copper level of the fluid. This test strip will retain that color for at least 30 days, says Phoenix. If there is no copper in the fluid, the pad will remain white.

In May 2005, the Motorist Assurance Program (MAP) made history by adopting the first automotive standard and guideline for brake fluid replacement. MAP found, though using FASCAR technology over five years of field testing, that monitoring copper levels in brake fluid is the most effective means for determining when corrosion inhibitors have become depleted and when brake fluid should be replaced. The standard is now included in the automotive industry guidelines called Uniform Inspection and Communication Standards (UICS). The new Brake Fluid UICS requires that when copper levels in brake fluid exceed 200 ppm, the fluid should be replaced.

According to the new MAP guideline, when the FASCAR Rating indicates that copper levels exceed 200 ppm, "the brake fluid does not meet design specifications" and requires replacement with OE recommended fluid. This means that even though the fluid is still capable of stopping the vehicle, it must still be replaced.

Research conducted in the development of FASCAR technology indicates that vehicle owners should closely monitor fluid once it reaches 100 ppm, as corrosion can very quickly accelerate to 200 ppm and beyond. Research to date on corrosion rates in ABS suggests that brake fluid should be tested for copper levels after about 20 months in service and thereafter, about as often as the vehicle's recommenced oil change or every 3,000 miles.

Figure 2. StripDip Brake Fluid Test Strip (Photo: Phoenix Systems)

FASCAR technology is available to professional technicians, marketed under the StripDip brand name through distributors across the country. According to Phoenix Systems, the FASCAR System provides automotive technicians with a quick and accurate visual test to determine whether a customer's brake system should be flushed and its fluid replaced.

One important feature of the product is its ability to assess the "virtual age" of a vehicle's brake fluid. For instance, while the fluid may only have been in the vehicle for 12,000 miles, the combination of the owner's driving and braking practices may result in the fluid having a virtual age and wear that is much higher. Having a quick visual tool can help shops capture brake maintenance business, while helping them to educate customers and keep roads safer for all.

(Sources: Phoenix Systems, NHTSA, NIST, MAP)