Actuation Systems

We can guarantee functional ABS Sensor stability and reliability in all conditions, from -40oC up to +150 oC. That’s because we thoroughly test and examine all of our ABS Sensors to the extreme. Our testing processes make sure that all TRW Aftermarket ABS Sensors are precisely manufactured to our exacting standards and follow the same structure as OE parts. Because if the magnet or chip is out of place by just one degree, it can lead to a loss of signal strength by up to 30%, which can prove dangerous for drivers. Track and road testing takes place during both the development and production stages and with premium-quality polymers used in our entire ABS Sensor range, you can trust that you’re fitting your customer’s vehicle with an ABS Sensor of the very highest standard.

As part of the TRW drum brake and actuation range, our ABS sensors offer outstanding safety and protection for a variety of vehicles. With more than 540 part numbers in the ABS sensor field we have everything covered, allowing vehicles to process precise data at all times.

Our premium materials include shrink-wrapped signal and power cables, premium-quality silicon and precise cable ducts that ensure a perfect level of impermeability throughout the life of the sensor.

ABS sensors carry out a very simple function: they measure the rotational speed of the wheel and send the results to the ABS control unit. Regulatory action will then be taken by the car in line with this information. For example, if the ABS sensor registers varying wheel speeds (which could lead to a loss of adhesion) the valves in the ABS hydraulic section will reduce the brake pressure until it is rotating freely once again. This process takes place multiple times a second, which means ABS sensors carry out a job that no human could manage.

ABS sensors also provide the data that they collect to other advanced systems throughout the car such as ESP, ASR, hill descent control and the integrated navigation systems where fitted. As the most heavily stressed part of the braking system, they are incredibly important to the performance of most cars, which means faulty parts need to be fixed as soon as issues are detected.

TRW ABS sensors have undergone a huge amount of change and development since introduction to the market, which means they are available in a variety of designs depending on specific car requirements.

The two basic types are active and passive ABS sensors.

Active sensors need an external energy source to operate and are designed for toothed/magnetic encoder wheels. There are also two types of active sensors, Hall sensors and Magneto Resistive sensors.

• The Hall sensor reacts to changes in magnetic fields with a voltage difference which is transmitted to the control unit as a clearly defined square wave signal. Hall sensors record the wheel speed via a segmented disc that rotates with the wheel or a ring with alternating magnetic fields (magnetic encoder). Hall sensors are highly precise but require a precise installation position.
• The magneto-resistive AMR sensors are currently regarded as the most advanced but also the most expensive ABS sensors. Their great advantage over the other designs is their ability to detect the rotational direction of the wheels. The signal is extremely precise and AMR sensors are practically tolerant to their installation position. The encoder disc comprises magnetic arc segments which cause a clear change in resistance when passing the sensor. For the control unit, this change acts as a parameter for the wheel’s rotational speed and direction.

Passive sensors require a toothed wheel and only start to operate when the wheel reaches a certain rotational speed. They are larger than active sensors and less precise, which means their presence in modern vehicles is becoming scarcer, but given the simplicity of the design they are easier to check and often more robust. TRW passive sensors are built with a coil around a magnetic core, this permanent magnet creates a magnetic field. As the toothed wheel turns, it changes the field, which then induces an electrical current depending on whether there is a tooth or not.

At TRW we have built a reputation for creating effective products that minimise environmental impact: it’s all part of our pioneering approach. The carefully formulated TRW Aftermarket Brake Cleaner is an important accessory that’s seriously effective and fast acting, but it’s also CFC free and contains no Trichloroethane.

Because we understand precisely what challenges you face when working on your customers’ vehicles, we create products that meet those challenges head on. Even in something as simple as a brake cleaner, attention to detail makes the difference.

The powerful 500 ml aerosol design makes it easy for you to get at difficult and restricted places in the brake system, and you will find that the spray works perfectly at any angle and even upside down. The task will be quicker and hassle-free, while the results will simply be better. We’ve thought carefully about TRW Aftermarket Brake Cleaner, so all you have to do is use it and appreciate the benefits.

With TRW Brake Cleaner you know you’re getting the same quality, effectiveness and value that you would with any of our components.

It’s easy to forget the importance of a Brake Hose among the many parts that make up a braking system.

In simple terms, the Brake Hose is a safety critical item on all vehicles. Operating under extreme stress whenever the brakes are used, they need to be checked regularly, as any faults will lead to a loss of brake fluid. This will mean a drop in pressure, which can lead to catastrophic brake failure.

The only way to find out whether a Brake Hose is working properly or not is to carry out a visual inspection. If cracks or leaks are visible it could be an indication that the whole brake network is damaged, as most brake parts wear out at the same rate as each other. TRW recommends that Brake Hoses are changed every five years or 31,000 miles (50,000 km) to make sure that safety isn’t compromised at any point.

Manufactured to TRW’s OE specification, our Brake Hose programme was awarded first place in an industry benchmark test for Volumetric Expansion carried out by the Automotive Manufacturers Equipment Compliance Agency (AMECA). The test revealed the exceptionally low volumetric expansion rate of our products compared to competitors, offering drivers superior pedal feel and improved stopping times.

TRW Brake Hoses have been crafted with modern cars in mind, as exact concentric fitting holes make sure there is a free flow of brake fluid. This is especially important for vehicles with advanced Anti-Lock Braking Systems (ABS) and Electronic Stability Control (ESC) as it allows for optimal pressure dump.

TRW provides high-pressure Brake Hoses made from rubber, Polytetrafluoroethylene (PTFE), steel or a combination of rubber and steel. Using these materials allows us to provide a product that has high resistance to humidity, chemicals and fuels and ensure that all of our hoses are produced in line with the Equipment Compliance Notification by AMECA. This means that all Brake Hoses from TRW are produced to not just meet but exceed the stringent OE standards, as well as the international specifications SAE J1401 and FMVSS 106.

Fitted with 100% zinc coated end fittings, our Brake Hoses are protected against rust, and with four layer high-quality fabrics, the hoses that we supply have exceptional flexibility and resistance to atmosphere as well as chemicals in fuels and grease.

Occupying the best European vehicle parc coverage position, as well as 1,400+ references and extensive coverage of Japanese and Korean vehicles, we can help you serve almost any customer. The range of Brake Hoses from TRW covers a wide range of manufacturers, including Honda, Toyota, Kia, Mazda, Nissan and Hyundai.

The only way to ensure that our hoses perform on the road in high-pressure situations is to test them to the extreme. This is exactly what we do, over and over again. Our testing process features:

• A pressure test up to 200 bar
• 100% leakage examination
• Destructive burst test up to 1100 bar
• Brake fluid compatibility test – conducted in an oven heated to 120oC for three days
• High pressure assessment test
• Volumetric expansion test
• Whip check to ensure a constant pressure of 20 bar and at 800 revs/minute
• Tensile test

TRW Aftermarket offers 1334 part numbers in the brake master cylinder range, which covers 72% of the European vehicle parc. What’s more, our extensive range includes brake master cylinders for most Asian car applications. With TRW Aftermarket Brake Master Cylinders you can give your customers excellent service from a premium range that offers increasingly wide coverage, all backed by more than 100 years of TRW experience as an original equipment aftermarket leader.

To meet the growing need across the automotive world for lighter components that maximise safety, we’re increasingly supplying our brake master cylinders in lightweight aluminium bodies as well as in steel or cast iron. Our aluminium brake master cylinders reduce weight, while retaining performance and guaranteeing long part lifespan. As a global leader in the design, development and manufacture of safety critical, original equipment braking, steering and suspension parts and systems, we’ve invested in innovation to deliver lightweight parts that deliver a heavyweight performance, and will continue to do so in the years ahead.

The exceptional performance of TRW Aftermarket Brake Master Cylinders is available from a high coverage range of parts, all supplied with fitting accessories, so you can fit unmatched original equipment quality fast. Everything we do at TRW has one objective – to make sure that garages and installers are able to satisfy customers profitably – and that’s been proven time and again right across our brake master cylinder range.

The steel and cast iron brake master cylinders in our range are coated with the latest chrome 6-free ‘silver’ finish. That means longer brake master cylinder lifespan and less damage to the environment – and you’ll be in line with EU directive EU 2000/53/EG. As the need for safety and the speed of technological change creates a need for ever more complex parts, we’ll give you the innovations that mean you can serve better products to more customers to keep your business turning.

We evaluate every element of each brake master cylinder to maximise safety. We do this through meticulous testing. All TRW Aftermarket Brake Master Cylinders are 100% end of line tested to ensure that they conform to TRW’s stringent original equipment quality standards, and we also put them through rigorous testing in the lab with up to one million cycles. In fact, we’re so confident of the quality of our brake master cylinders that we offer an additional three-year guarantee in the event of a defect in material or workmanship.

All TRW Aftermarket Brake Master Cylinders are fitted with original equipment specification rubber seals and dust caps, which means they are far more resistant to ageing. In the automotive industry, the TRW brand on brake master cylinder castings and dust caps has always been a guarantee of premium product quality, and our recent innovations show that we’re still working to enhance their quality even further. Our aftermarket range of brake master cylinders now incorporates the latest advances developed for original equipment, including fixed seals. Put this together with our extended range of aluminium wheel cylinders, which deliver reduced vehicle weight as well as extended part lifetime – plus our extended guarantee for 3 years or 60,000 mile (100,000 km) – and our brake master cylinder range has the seal of quality in more ways than one.

So how important is the quality of a brake master cylinder? The simple answer is vitally important. The ‘invisible’, safety critical parts of the braking system, hidden under a drum or inside the car, are often not given the same degree of consideration as brake discs and pads. But if drum brake and actuation system components such as brake master cylinders, brake hoses or brake fluid are not working properly it can contribute to a serious reduction in braking performance. Checking these parts regularly and fitting good quality, OE matching aftermarket products when necessary is essential. That’s why the premium quality and wide coverage of our TRW Aftermarket range of brake master cylinders enables garages, installers and end users alike to maximise safety for almost any vehicle.