Was the Hydraulic Brake System Diagnostic Check performed?

-

Go to Step 2

Go to Hydraulic Brake Diagnostic System Check .

Inspect the vehicle for overloading.

Refer to Loading Your Vehicle in the Vehicle Owner's Manual.

Is there excessive vehicle weight?

-

Go to Step 3

Go to Step 4

Remove the extra weight from the vehicle.

Has the excessive weight been removed?

-

Go to Step 25

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Inspect the disc brake pads and for the following:

Refer to Brake Pad Inspection in Disc Brakes.

Do any of the above conditions apply?

-

Go to Step 5

Go to Step 6

Replace the brake linings. Refer to Brake Pads Replacement in Disc Brakes.

Is the repair complete?

-

Go to Step 25

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Inspect the brake rotor surface for excessive thickness variation. Refer to Brake Rotor Thickness Variation Check in Disc Brakes.

Is the rotor thickness variation beyond specification?

0.010  mm (0.003  in). Drums 0.15 mm (0.006 in).

Go to Step 7

Go to Step 8

1. Resurface the brake rotor. Refer to Brake Rotor Refinishing in Disc Brakes.
2. If refinishing the brake rotor results in a thickness that is less than the thinnest (Refinished) thickness, replace the rotor. Refer to Brake Rotor Replacement in Disc Brakes.

Is the repair complete?

Refer to Component Specifications in Disc Brakes.

Go to Step 25

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Inspect the brake rotors for excessive lateral runout. Refer to Brake Rotor Lateral Runout Check.

Is the brake rotor runout excessive?

-

Go to Step 9

Go to Step 10

1. Resurface the brake rotor. Refer to Refinishing Brake Rotors in Disc Brakes.
2. If refinishing the brake rotor results in a thickness that is less than the thinnest (Refinished) thickness, replace the rotor. Refer to Brake Rotor Replacement in Disc Brakes.

Is the repair complete?

Refer to Component Specifications in Disc Brakes.

Go to Step 25

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Inspect brake assembly for missing or loose attachments. Refer to Brake Pad Inspection in Disc Brakes.

Are there missing attachments?

-

Go to Step 11

Go to Step 12

Tighten the attachments.

Is the repair complete?

-

Go to Step 25

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Inspect the master cylinder for leakage. Refer to Master Cylinder Diagnosis.

Is there leakage?

-

Go to Step 13

Go to Step 14

Overhaul the master cylinder. Refer to Master Cylinder Overhaul.

Is the repair complete?

-

Go to Step 25

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Inspect the hydraulic brake system for leaks.

Refer to Brake Fluid Leaks and Brake Hose and Pipe Diagnosis.

Is there any sign of leakage?

-

Go to Step 15

Go to Step 17

1. Tighten the brake hose or pipe fittings. Refer to Fastener Tightening Specifications.
2. Start the engine.
3. Press the brake pedal several times.
4. Turn OFF the engine.
5. Inspect the hydraulic brake system for leaks.

Has the leak returned?

-

Go to Step 16

Go to Step 17

Replace the brake hose or pipe as necessary. Refer to Front Brake Hose Replacement or Pipe Replacement (Front ), Rear Hose Replacement, Pipe Replacement (Rear).

Is the repair complete?

-

Go to Step 25

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Inspect the brake system for air. Refer to Hydraulic Brake System Bleeding.

Is there air in the system?

-

Go to Step 18

Go to Step 19

Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding.

Is the repair complete?

-

Go to Step 25

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Inspect the brake fluid for contamination. Refer to Brake Fluid and Brake Fluid Handling.

Is the brake fluid contaminated?

-

Go to Step 20

Go to Step 21

Flush the hydraulic brake system. Refer to Hydraulic Brake System Flushing.

Is the repair complete?

-

Go to Step 25

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Inspect the rear axle oil seal for leakage.

Is the seal leaking?

-

Go to Step 22

Go to Step 23

Replace the rear axle oil seal. Refer to Oil Seal and/or Bearing Replacement in Rear Drive Axle.

Is the repair complete?

-

Go to Step 25

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1. Remove the brake caliper. Refer to Brake Caliper Replacement in Disc Brakes.
2. Inspect the brake caliper for leakage. Refer to Brake Caliper Inspection.

Does the brake caliper show signs of leakage?

-

Go to Step 24

System OK

Overhaul the brake caliper. Refer to Brake Caliper Overhaul in Disc Brakes.

Is the repair complete?

-

Go to Step 25

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Verify proper brake system operation.

Does the original condition still exist?

-

Verify the customer complaint. Begin the diagnosis again. Go to Step 1

System OK