Was the Hydraulic Brake System Diagnostic Check performed?

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Go to Step 2

Go to Brake System Diagnosis

Inspect the vehicle for overloading.

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

Is there excessive vehicle weight?

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Go to Step 3

Go to Step 4

Remove the extra weight from the vehicle.

Has the excessive weight been removed?

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Go to Step 25

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Inspect the disc brake pads and brake shoe linings for the following:

Refer to Brake Pad Inspection .

Do any of the above conditions apply?

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Go to Step 5

Go to Step 6

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

Is the repair complete?

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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?

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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 and Component Specifications in Disc Brakes.

Is the repair complete?

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Go to Step 2

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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?

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Go to Step 9

Go to Step 10

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?

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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?

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Go to Step 11

Go to Step 12

Tighten or replace the attachments as necessary.

Is the repair complete?

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Go to Step 25

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

Is the master cylinder leaking?

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Go to Step 13

Go to Step 14

Overhaul the master cylinder. Refer to Master Cylinder Overhaul .

Is the repair complete?

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Go to Step 25

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Inspect the hydraulic brake system for leaks.

Refer to Brake Fluid Leak .

Is there any sign of leakage?

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Go to Step 15

Go to Step 19

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 the engine to OFF.
5. Inspect the hydraulic brake system for leaks.

Has the leak returned?

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Go to Step 16

Go to Step 17

Replace the brake hose or pipe as necessary.

Is the repair complete?

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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?

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Go to Step 18

Go to Step 19

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

Is the repair complete?

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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?

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Go to Step 20

Go to Step 21

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

Is the repair complete?

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Go to Step 25

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Inspect the rear axle oil seal for leakage.

Is the seal leaking?

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Go to Step 22

Go to Step 23

Replace the rear axle oil seal. Refer to Rear Hub and Bearing Replacement in Rear Drive Axle.

Is the repair complete?

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Go to Step 25

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Inspect the brake caliper for leakage.

Does the brake caliper show signs of leakage?

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Go to Step 24

Go to Step 25

Overhaul or replace the brake caliper. Refer to Brake Caliper Overhaul and Brake Caliper Replacement in Disc Brakes.

Is the repair complete?

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Go to Step 25

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Verify proper brake system operation.

Does the original condition still exist?

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Go to Step 1

System OK