Was the Hydraulic Brake System Diagnostic Check performed?

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Go to Step 2

Go to Brake System Diagnosis

Inspect the hydraulic brake system for leaks. Refer to Brake Fluid Leak .

Are there any leaks?

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Go to Step 3

Go to Step 5

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 off.
5. Inspect the hydraulic brake system for leaks.

Has the leak returned?

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Go to Step 4

Go to Step 29

Replace the brake hose or pipe as necessary.

Is the repair complete?

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Go to Step 29

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

Refer to the appropriate procedure:

Do any of the above conditions apply?

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Go to Step 6

Go to Step 7

Replace the brake linings. Refer to the appropriate procedure:

Is the repair complete?

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Go to Step 29

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Inspect the following brake caliper assembly components for corrosion:

Refer to Brake Caliper Inspection in Disc Brakes.

Are any of the above components corroded or sticking?

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Go to Step 8

Go to Step 9

Replace the corroded components. Refer to the appropriate procedure in Disc Brakes:

Is the repair complete?

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Go to Step 29

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Inspect the brake assembly for loose, missing, or broken components.

Refer to the appropriate procedure:

Are there loose, missing, or broken brake assembly components?

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Go to Step 10

Go to Step 11

Tighten or replace the components as necessary. Refer to the appropriate procedure:

Is the repair complete?

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Go to Step 29

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Inspect the wheel cylinders for leakage or binding?

Do the wheel cylinders show signs of leakage or binding?

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Go to Step 12

Go to Step 13

Overhaul or replace the wheel cylinder. Refer to Wheel Cylinder Overhaul or Wheel Cylinder Replacement in Drum Brakes.

Is the repair complete?

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Go to Step 29

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1. Inspect the brake pedal assembly for bent or misaligned components.
2. Inspect the brake pedal for binding between the pedal and the booster input rod.

Is the brake pedal binding?

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Go to Step 14

Go to Step 15

Disassemble and realign or replace any components as necessary. Replace the brake pedal if necessary. Refer to Brake Pedal Replacement .

Is the repair complete?

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Go to Step 29

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Inspect the brake pedal for interference with other components. Inspect the brake pedal area for the following:

Are there any loose or interfering components?

--

Go to Step 16

Go to Step 17

Realign or reposition any components as necessary.

Is the repair complete?

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Go to Step 29

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Inspect the vehicle for collapsed, bent, or kinked brake lines or hoses.

Are the brake hoses or the brake pipes collapsed, bent, or kinked?

--

Go to Step 18

Go to Step 19

Reroute or replace the brake hoses or pipes as necessary.

Is the repair complete?

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Go to Step 29

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1. Remove the master cylinder reservoir cover.
2. Rapidly apply the brake pedal 3 cm (1 in) while an assistant observes the brake fluid in the reservoir.

Does the fluid surface in the forward reservoir show movement or spouting?

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Go to Step 20

Go to Step 21

1. Install the master cylinder reservoir cover.
2. Loosen the master cylinder mounting nuts 13 mm (½ in).
3. Separate the master cylinder from the hydraulic brake booster.
4. Apply the brake pedal 3 cm (1 in).

Does the booster output rod move?

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Go to Step 21

Go to Step 22

Replace the master cylinder. Refer to Master Cylinder Replacement .

Is the repair complete?

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Go to Step 29

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Replace the brake booster. Refer to Power Brake Booster Replacement .

Is the repair complete?

--

Go to Step 29

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Remove the master cylinder cover and inspect the brake fluid for contamination. Is the brake fluid contaminated?

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Go to Step 24

Go to Step 25

Flush the hydraulic brake system. Refer to Hydraulic Brake System Flushing . Is the repair complete?

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Go to Step 29

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Inspect the master cylinder outlet ports for restricted passages. Refer to Hydraulic Brake System Bleeding .

Are the outlet ports restricted?

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Go to Step 26

Go to Step 27

1. Overhaul the master cylinder. Refer to Master Cylinder Overhaul .
2. Flush the hydraulic brake system. Refer to Hydraulic Brake System Bleeding .

Is the repair complete?

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Go to Step 29

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Inspect the brake pipes and the brake hoses for restricted passages. Refer to Hydraulic Brake System Bleeding .

Inspect for the following:

Do any of the above conditions apply?

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Go to Step 29

System OK

1. Determine the area of the restriction. This involves the disassembly of individual brake lines and testing for low fluid output.
2. Flush the individual brake line or the brake hose.
3. If the restriction cannot be removed, replace the brake hose or the brake pipe as necessary.
4. Flush the hydraulic brake system. Refer to Hydraulic Brake System Bleeding .

Is the repair complete?

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Go to Step 29

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Verify proper brake system operation.

Does the original condition still exist?

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Verify the customer complaint. Go to Step 1

System OK