| Brake Fluid Compatibility |
FMVSS No. 116; ISO 4925 |
Materials in contact with the fluid should be compatible with the specified glycol-based or silicone-based brake-fluid category. |
Material declaration, compatibility test report, seal specification, and fluid exposure results. |
Reduces swelling, shrinkage, softening, cracking, and premature seal failure. |
| DOT 3 Fluid Performance |
FMVSS No. 116; ISO 4925 Class 3 |
Minimum dry equilibrium reflux boiling point: 205°C Minimum wet equilibrium reflux boiling point: 140°C |
Batch certificate showing boiling-point test results and laboratory test method. |
Common glycol-ether specification for many passenger-vehicle braking systems. |
| DOT 4 Fluid Performance |
FMVSS No. 116; ISO 4925 Class 4 |
Minimum dry equilibrium reflux boiling point: 230°C Minimum wet equilibrium reflux boiling point: 155°C |
Certificate of analysis, batch traceability, and independent verification where required. |
Widely specified for vehicles requiring a higher boiling-point margin than DOT 3. |
| DOT 5.1 Fluid Performance |
FMVSS No. 116; ISO 4925 Class 5 |
Minimum dry equilibrium reflux boiling point: 260°C Minimum wet equilibrium reflux boiling point: 180°C |
Boiling-point report, viscosity report, and product identification by fluid class. |
Used where high boiling performance and glycol-fluid compatibility are required. |
| Silicone Fluid Separation |
FMVSS No. 116 DOT 5 |
DOT 5 silicone fluid must not be treated as interchangeable with glycol-based DOT 3, DOT 4, or DOT 5.1 fluids. |
Clear fluid-category labeling, separate handling instructions, and compatibility declaration. |
Prevents incorrect fluid selection and chemical incompatibility in service applications. |
| Low-Temperature Viscosity |
FMVSS No. 116; applicable ISO 4925 class |
Viscosity must remain within the limit specified by the selected fluid class at the applicable low test temperature. |
Viscosity test report identifying test temperature, measured value, method, and fluid batch. |
Supports reliable pump priming, valve response, and brake-fluid movement in cold climates. |
| Pump Pressure Capability |
Application-specific engineering requirement |
Rated operating pressure, proof pressure, and leakage limit must be defined for the intended brake-fluid pumping application. |
Pressure-cycle test, proof-pressure record, leak test, and calibrated-equipment information. |
A universal pressure value should not be assumed; the vehicle or test-system design determines the correct rating. |
| Volumetric Accuracy |
Purchaser-defined dispensing specification |
Specify target delivery volume, repeatability, and allowable deviation for each pump stroke or operating cycle. |
Production capability study, repeated-cycle measurement data, and inspection plan. |
Important for controlled filling, bleeding, flushing, and automated brake-service equipment. |
| Seal and Diaphragm Quality |
Fluid-specific elastomer compatibility requirement |
Seal material, hardness range, dimensional tolerances, and fluid-aging performance must be documented for the selected fluid. |
Seal material certificate, dimensional inspection report, aging test, and cross-section approval sample. |
Helps prevent internal bypass, external leakage, and loss of pumping efficiency. |
| Cleanliness and Moisture Control |
Purchaser-defined cleanliness specification |
Internal passages should be free from machining chips, dust, loose particles, and uncontrolled moisture before packaging. |
Cleanliness inspection procedure, particle-control record, capped ports, and packaging specification. |
Moisture and contamination can reduce brake-fluid performance and damage precision components. |
| Corrosion Resistance |
Fluid-contact material requirement; ISO 4925-related performance considerations |
Metallic fluid-contact surfaces should resist corrosion throughout the declared service and storage conditions. |
Material grade declaration, corrosion test report, surface-treatment specification, and salt or fluid exposure data where applicable. |
Supports long-term reliability in humid, coastal, and winter-road environments. |
| Leak Tightness |
Purchaser-defined acceptance criterion |
No visible external leakage or unacceptable pressure decay during the specified static and dynamic test sequence. |
100% production leak-test record or sampling plan, test pressure, hold time, and acceptance limit. |
Directly affects safety, fluid consumption, maintenance intervals, and customer claims. |
| Dimensional Interchangeability |
Approved drawing and interface specification |
Mounting points, port dimensions, thread type, shaft or coupling geometry, and reservoir interface must match the approved design. |
2D drawing, 3D model, gauge report, first-article inspection, and interface sample approval. |
Prevents installation delays and compatibility problems across international service platforms. |
| Traceability |
ISO 9001 quality-management practice |
Each production lot should be identifiable through a batch code linked to raw materials, inspection results, and release records. |
Lot numbering procedure, certificate of conformity, inspection records, and retention policy. |
Enables effective recalls, complaint investigation, and regulatory or customer audits. |
| Quality Management System |
ISO 9001; IATF 16949 where automotive supply applies |
Supplier should operate a documented quality system appropriate to the product risk and intended market. |
Current certificate, scope statement, audit report, corrective-action records, and process-control plan. |
Provides a structured basis for consistent manufacturing and continuous improvement. |
| Packaging and Storage |
Purchaser-defined logistics specification |
Seal all fluid ports, protect against dust and moisture, and state storage temperature, shelf-life, and handling requirements. |
Packaging drawing, shipping test record, storage instruction, and shelf-life declaration. |
Maintains pump cleanliness and seal condition during international transport and warehouse storage. |