Was the Hydraulic Brake System Diagnostic Check performed?

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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?

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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 23

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Inspect the disc brake pads for:

Refer to Brake Pad Inspection in Disc Brakes.

Do any of the above conditions apply?

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Go to Step 5

Go to Step 6

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

Is the repair complete?

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Go to Step 23

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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)

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 specification, replace the rotor. Refer to Front Brake Rotor Replacement or Rear Brake Rotor Replacement in Disc Brakes.

Is the repair complete?

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Go to Step 23

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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. Refsurface the brake rotor. Refer to Brake Rotor Refinishing in Disc Brakes.
2. If refinishing the brake rotors results in a thickness that is less than the specification, (Refinished) thickness, replace the rotor. Refer to Front Brake Rotor Replacement or Rear Brake Rotor Replacement in Disc Brakes.

Is the repair complete?

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Go to Step 23

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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

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Tighten the attachments.

Is the repair complete?

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Go to Step 23

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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

Replace the master cylinder. Refer to Master Cylinder Replacement .

Is the repair complete?

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Go to Step 23

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Inspect the hydraulic brake system for leaks.

Is there any sign of leakage?

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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?

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Go to Step 16

Go to Step 17

Replace the brake hose or pipe as necessary. Refer to Front Brake Hose Replacement or Rear Brake Hose Replacement and ISO Flares Replacement .

Is the repair complete?

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Go to Step 23

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Inspect the hydraulic brake system for air in the system. 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 23

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Inspect the brake fluid for contamination.

Is the brake fluid contaminated?

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Go to Step 20

Go to Step 23

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

Is the repair complete?

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Go to Step 23

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

Does the brake caliper show signs of leakage?

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Go to Step 22

System OK

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

Is the repair complete?

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Go to Step 23

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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