Step
| Action
| Yes
| No
|
DEFINITION: This diagnostic table is designed to diagnose ONLY the components of the HYDRAULIC brake system in order to determine if the HYDRAULIC brake system is operating properly. You will be directed by the appropriate Symptom table to go to other
brake system diagnostic tables as appropriate.
|
1
| Were you sent here from a Brake Symptom table?
| Go to
Step 2
| Go to
Diagnostic Starting Point - Hydraulic Brakes
|
2
| Inspect and adjust the brake fluid level in the brake master cylinder. Refer to
Master Cylinder Reservoir Filling.
Was the brake fluid level low?
| Go to
Step 3
| Go to
Step 4
|
3
|
- Inspect the brake fluid for the following conditions, indicating brake fluid contamination:
| • | Fluid separation, indicating two types of fluid are present |
| - | Swirled appearance - oil-based substance |
| - | Layered appearance - silicone-based substance |
| - | Cloudy appearance - moisture |
| - | Dark appearance/suspended particles in fluid - dirt, rust, corrosion, brake dust |
- Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for swelling, indicating fluid contamination.
Do any of the above conditions exist?
| Go to
Step 5
| Go to
Step 6
|
4
|
- Inspect the brake fluid for the following conditions, indicating brake fluid contamination:
| • | Fluid separation, indicating two types of fluid are present |
| - | Swirled appearance - oil-based substance |
| - | Layered appearance - silicone-based substance |
| - | Cloudy appearance - moisture |
| - | Dark appearance/suspended particles in fluid - dirt, rust, corrosion, brake dust |
- Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for swelling, indicating fluid contamination.
Do any of the above conditions exist?
| Go to
Step 5
| Go to
Step 12
|
5
|
- Flush the hydraulic brake system. Refer to
Hydraulic Brake System Flushing.
- If the brake fluid WAS contaminated with an oil-based or a silicone-based fluid, indicated by fluid separation and/or a swollen master cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform the following steps.
Refer to the procedures indicated.
| 2.1. | Remove ALL of the following components listed. Each component contains internal rubber seals/linings which have been contaminated. |
| 2.2. | Clean out the hydraulic brake pipes using denatured alcohol, or equivalent. |
| 2.3. | Dry the brake pipes using non-lubricated, filtered air. |
| 2.4. | Repair or replace ALL of the following components listed. Each component contains internal rubber seals/linings which have been contaminated. |
| • | Brake master cylinder reservoir: Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the reservoir using non-lubricated, filtered air, or if necessary, replace the brake master cylinder reservoir. |
| • | Replace the brake master cylinder reservoir cap diaphragm. |
- If the brake fluid was NOT contaminated with an oil-based fluid, but WAS contaminated with water or dirt, rust, corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm which may have allowed moisture or dirt to enter
the system.
- Refill and bleed the hydraulic brake system. Refer to
Hydraulic Brake System Bleeding.
Did you complete the operation and any required repairs and/or replacements?
| Go to
Step 9
| --
|
6
|
- Inspect the following hydraulic brake system components for external fluid leaks Repair or replace any of the components found to be leaking brake fluid. Refer to the appropriate procedures:
| • | Brake master cylinder reservoir cap diaphragm |
- If you repaired or replaced any of the brake system components listed, bleed the hydraulic brake system. Refer to
Hydraulic Brake System Bleeding. While bleeding the hydraulic brake system, observe for the
following conditions:
| • | The presence of air in the system at a bleeder valve location other than at the repair location, except if the brake master cylinder was replaced |
| • | An unrestricted and even flow of brake fluid per axle during the bleeding procedure |
Did you find and correct a condition?
| Go to
Step 7
| Go to
Step 12
|
7
| Was there air in the system at a bleeder valve location other than at the repair location, except if the brake master cylinder was replaced?
| Go to
Step 19
| Go to
Step 8
|
8
| Was the flow of brake fluid unrestricted and even per axle during the bleeding procedure?
| Go to
Step 9
| Go to
Step 10
|
9
| Inspect the hydraulic function of the brake calipers for proper operation. Refer to
Hydraulic Brake Component Operation Visual Inspection.
Was the hydraulic function of the brake calipers operating properly?
| Go to
Step 21
| Go to
Step 14
|
10
| Was the flow of brake fluid restricted or uneven through front axle hydraulic components during the bleeding procedure?
| Go to
Step 13
| Go to
Step 11
|
11
| Was the flow of brake fluid restricted or uneven through rear axle hydraulic components during the bleeding procedure?
| Go to
Step 17
| --
|
12
| Inspect the hydraulic function of the brake calipers for proper operation. Refer to
Hydraulic Brake Component Operation Visual Inspection.
Was the hydraulic function of the brake calipers operating properly?
| Go to
Step 15
| Go to
Step 13
|
13
| Determine if the brake caliper is restricting the flow of brake fluid and/or not operating properly:
- Raise and support the vehicle. Refer to
Lifting and Jacking the Vehicle.
- Remove the tire and wheel assemblies. Refer to
Tire and Wheel Removal and Installation.
- Open the suspected caliper bleeder valve.
- Using a large C-clamp, compress the caliper piston and observe for an unrestricted flow of brake fluid and for free movement of the caliper piston.
- Close the caliper bleeder valve.
Was the flow of brake fluid unrestricted and did the caliper piston move freely?
| Go to
Step 17
| Go to
Step 14
|
14
| Repair or replace any brake caliper that was not operating properly. Refer to the appropriate procedure:
Did you complete the repair and/or replacement?
| Go to
Step 21
| --
|
15
| Bleed the hydraulic brake system to observe for the presence of air in the system and to observe for an unrestricted and even flow of brake fluid per axle during the bleeding procedure. Refer to
Hydraulic Brake System Bleeding.
Was there air in the system?
| Go to
Step 19
| Go to
Step 16
|
16
| Was the flow of brake fluid unrestricted and even per axle during the bleeding procedure?
| Go to
Step 21
| Go to
Step 17
|
17
|
- Inspect the hydraulic brake pipes and flexible brake hoses for signs of a fluid restriction; such as being bent, kinked, pinched or damaged. Refer to
Brake Pipe and Hose Inspection.
- Replace any of the hydraulic brake pipes and/or flexible brake hoses found to be bent, kinked, pinched, or damaged. Refer to the following procedures as necessary:
- If none of the hydraulic brake pipes or flexible brake hoses were visibly bent, kinked, pinched, or damaged, replace the hydraulic brake flex hose at the restricted location.
Did you find and correct a condition?
| Go to
Step 21
| Go to
Step 18
|
18
| Replace the brake pressure modulator valve (BPMV), in order to correct the hydraulic brake dynamic rear proportioning mechanical operation. Refer to
Brake Pressure Modulator Valve Replacement Non-Hybrid Less than 3900 kg (8600 lb) GVW
or
Brake Pressure Modulator Valve Replacement Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW.
Did you complete the replacement?
| Go to
Step 21
| --
|
19
|
- Inspect the hydraulic brake system components for brake fluid seepage at a seal and/or fitting location, which may have drawn air into the system.
- Inspect the hydraulic brake system components for evidence of a recent repair, which may have introduced air into the system.
- Repair or replace any of the components found to be installed incorrectly or seeping brake fluid.
Did you find and correct a condition?
| Go to
Step 21
| Go to
Step 20
|
20
|
- Inspect the brake master cylinder for internal fluid leaks. Refer to
Brake System Internal Leak Test.
- Repair or replace the brake master cylinder if it is found to be leaking brake fluid internally. Refer to
Master Cylinder Replacement.
Did you find and correct a condition?
| Go to
Step 21
| Return to Symptom Table
|
21
| Install or connect components that were removed or disconnected during diagnosis.
Did you complete the operation?
| Hydraulic Brake System OK
Return to Symptom Table
| --
|
Step
| Action
| Yes
| No
|
DEFINITION: This diagnostic table is designed to diagnose ONLY the components of the HYDRAULIC brake system in order to determine if the HYDRAULIC brake system is operating properly. You will be directed by the appropriate Symptom table to go to other
brake system diagnostic tables as appropriate.
|
1
| Were you sent here from a Brake Symptom table?
| Go to
Step 2
| Go to
Diagnostic Starting Point - Hydraulic Brakes
|
2
|
- Inspect and adjust the brake fluid level in the brake master cylinder. Refer to
Master Cylinder Reservoir Filling.
- Inspect the brake fluid for the following conditions, indicating brake fluid contamination:
| • | Fluid separation, indicating two types of fluid are present |
| - | Swirled appearance - oil-based substance |
| - | Layered appearance - silicone-based substance |
| - | Cloudy appearance - moisture |
| - | Dark appearance/suspended particles in fluid - dirt, rust, corrosion, brake dust |
- Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for swelling, indicating fluid contamination.
Do any of the above fluid contamination conditions exist?
| Go to
Step 3
| Go to
Step 4
|
3
|
- Flush the hydraulic brake system. Refer to
Hydraulic Brake System Flushing.
- If the brake fluid WAS contaminated with an oil-based or a silicone-based fluid, indicated by fluid separation and/or a swollen master cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform the following steps.
Refer to the procedures indicated.
| 2.1. | Remove ALL of the following components listed. Each component contains internal rubber seals/linings which have been contaminated. |
| 2.2. | Clean out the hydraulic brake pipes using denatured alcohol, or equivalent. |
| 2.3. | Dry the brake pipes using non-lubricated, filtered air. |
| 2.4. | Repair or replace ALL of the following components listed. Each component contains internal rubber seals/linings which have been contaminated. |
| • | Brake master cylinder reservoir: Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the reservoir using non-lubricated, filtered air, or if necessary, replace the brake master cylinder reservoir. |
| • | Replace the brake master cylinder reservoir cap diaphragm. |
- If the brake fluid was NOT contaminated with an oil-based fluid, but WAS contaminated with water or dirt, rust, corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm which may have allowed moisture or dirt to enter
the system.
- Refill and bleed the hydraulic brake system. Refer to
Hydraulic Brake System Bleeding.
Did you complete the operation and any required repairs and/or replacements?
| Go to
Step 8
| --
|
4
| Was the brake fluid level low?
| Go to
Step 5
| Go to
Step 11
|
5
|
- Inspect the following hydraulic brake system components for external fluid leaks Repair or replace any of the components found to be leaking brake fluid. Refer to the appropriate procedures:
| • | Brake master cylinder reservoir cap diaphragm |
- If you repaired or replaced any of the brake system components listed, bleed the hydraulic brake system. Refer to
Hydraulic Brake System Bleeding. While bleeding the hydraulic brake system, observe for the
following conditions:
| • | The presence of air in the system at a bleeder valve location other than at the repair location, and/or air reappearing in the brake master cylinder reservoir, except if the brake master cylinder was replaced |
| • | An unrestricted and even flow of brake fluid per axle during the bleeding procedure |
Did you find and correct a condition?
| Go to
Step 6
| Go to
Step 11
|
6
| Was there air in the system at a bleeder valve location other than at the repair location, and/or air reappearing in the brake master cylinder reservoir, except if the brake master cylinder was replaced?
| Go to
Step 18
| Go to
Step 7
|
7
| Was the flow of brake fluid unrestricted and even per axle during the bleeding procedure?
| Go to
Step 8
| Go to
Step 9
|
8
| Inspect the hydraulic function of the brake calipers for proper operation. Refer to
Hydraulic Brake Component Operation Visual Inspection.
Was the hydraulic function of the brake calipers operating properly?
| Go to
Step 20
| Go to
Step 13
|
9
| Was the flow of brake fluid restricted or uneven through front axle hydraulic components during the bleeding procedure?
| Go to
Step 12
| Go to
Step 10
|
10
| Was the flow of brake fluid restricted or uneven through rear axle hydraulic components during the bleeding procedure?
| Go to
Step 16
| --
|
11
| Inspect the hydraulic function of the brake calipers for proper operation. Refer to
Hydraulic Brake Component Operation Visual Inspection.
Was the hydraulic function of the brake calipers operating properly?
| Go to
Step 14
| Go to
Step 12
|
12
| Determine if the brake caliper is restricting the flow of brake fluid and/or not operating properly:
- Raise and support the vehicle. Refer to
Lifting and Jacking the Vehicle.
- Remove the tire and wheel assemblies. Refer to
Tire and Wheel Removal and Installation.
- Open the suspected caliper bleeder valve.
- Using a large C-clamp, compress the caliper piston and observe for an unrestricted flow of brake fluid and for free movement of the caliper piston.
- Close the caliper bleeder valve.
Was the flow of brake fluid unrestricted and did the caliper piston move freely?
| Go to
Step 16
| Go to
Step 13
|
13
| Repair or replace any brake caliper that was not operating properly. Refer to the appropriate procedure:
Did you complete the repair and/or replacement?
| Go to
Step 20
| --
|
14
| Bleed the hydraulic brake system to observe for the presence of air in the system and to observe for an unrestricted and even flow of brake fluid per axle during the bleeding procedure. Refer to
Hydraulic Brake System Bleeding.
Was there air in the system?
| Go to
Step 18
| Go to
Step 15
|
15
| Was the flow of brake fluid unrestricted and even per axle during the bleeding procedure?
| Go to
Step 20
| Go to
Step 16
|
16
|
- Inspect the hydraulic brake pipes and flexible brake hoses for signs of a fluid restriction; such as being bent, kinked, pinched or damaged. Refer to
Brake Pipe and Hose Inspection.
- Replace any of the hydraulic brake pipes and/or flexible brake hoses found to be bent, kinked, pinched, or damaged. Refer to the following procedures as necessary:
- If none of the hydraulic brake pipes or flexible brake hoses were visibly bent, kinked, pinched, or damaged, replace the hydraulic brake flex hose at the restricted location.
Did you find and correct a condition?
| Go to
Step 20
| Go to
Step 17
|
17
| Replace the brake pressure modulator valve (BPMV), in order to correct the hydraulic brake dynamic rear proportioning mechanical operation. Refer to
Brake Pressure Modulator Valve Replacement.
Did you complete the replacement?
| Go to
Step 20
| --
|
18
|
- Inspect the hydraulic brake system components for brake fluid seepage at a seal and/or fitting location, which may have drawn air into the system.
- Inspect the hydraulic brake system components for evidence of a recent repair, which may have introduced air into the system.
- Repair or replace any of the components found to be installed incorrectly or seeping brake fluid.
Did you find and correct a condition?
| Go to
Step 20
| Go to
Step 19
|
19
|
- Inspect the brake master cylinder for internal fluid leaks. Refer to
Brake System Internal Leak Test.
- Inspect for brake pedal travel. Refer to
Brake Pedal Travel Measurement and Inspection.
- Repair or replace the brake master cylinder if it is found to be leaking brake fluid internally, and/or if the brake pedal travel exceeds specification and there is no damage to the pedal system or pushrod. Refer to
Master Cylinder Replacement.
Did you find and correct a condition?
| Go to
Step 20
| Return to Symptom Table
|
20
| Install or connect components that were removed or disconnected during diagnosis.
Did you complete the operation?
| Hydraulic Brake System OK
Return to Symptom Table
| --
|
