Was the Hydraulic Brake Diagnostic System Check performed?

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Go to Step 2

Go to Hydraulic Brake Diagnostic System Check

Is the operator riding the brake pedal?

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Advise customer of proper braking procedures

Go to Step 3

Inspect the vehicle for overloading. Refer to Loading Your Vehicle in the Vehicle Owner's Manual.

Is there excessive weight in the vehicle?

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Go to Step 4

Go to Step 5

Remove the extra weight from the vehicle.

Does the original condition still exist?

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Go to Step 5

Go to Step 19

Inspect the brake pedal assembly for the following:

Are the components misaligned or binding?

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Go to Step 6

Go to Step 7

Repair or replace the cause of misalignment.

Is the repair complete?

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Go to Step 19

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

Refer to Brake Pad Inspection in Disc Brakes or Brake Shoe Inspection in Drum Brakes.

Do any of the above conditions apply?

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Go to Step 8

Go to Step 9

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

Is the repair complete?

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Go to Step 19

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Inspect the brake rotors for the following:

Do any of the above conditions apply?

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Go to Step 10

Go to Step 11

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

Is the repair complete?

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Go to Step 19

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Inspect the master cylinder for the following:

Refer to Master Cylinder Diagnosis .

Do any of the above conditions apply?

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Go to Step 12

Go to Step 13

Overhaul the master cylinder. Refer to Master Cylinder Overhaul in Hydraulic Brakes.

Is the repair complete?

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Go to Step 19

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Inspect the hydraulic brake booster for leakage. Refer to Seal Leak Diagnosis .

Is the hydraulic brake booster leaking?

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Go to Step 14

Go to Step 15

Repair or replace the hydraulic brake booster. Refer to Hydraulic Brake Booster Accumulator Replacement or Power Brake Booster Replacement .

Is the repair complete?

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Go to Step 19

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Check for leaking brake pipes, hoses or connections. Refer to Brake Fluid Leak and Brake Hose and Pipe Diagnosis .

Are any of the above components leaking?

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Go to Step 16

Go to Step 17

Tighten the brake hose or pipe fitting. Refer to Fastener Tightening Specifications .

Is the repair complete?

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Go to Step 19

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Check the brake pipes and hoses for the following:

Refer to Hydraulic Brake System Flushing .

Do any of the above conditions apply?

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Go to Step 18

Go to Step 19

1. Determine the area of the restriction. This will involve the disassembly of the individual brake lines and checking for low or no fluid output.
2. Flush the individual brake line or hose. Refer to Hydraulic Brake System Flushing .
3. If the restriction cannot be removed, replace the brake hose or pipe as necessary. Refer to:

•	Front Brake Pipe Replacement

•	Front Brake Hose Replacement

•	Rear Brake Hose Replacement

•	Rear Brake Pipe Replacement

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

Is the repair complete?

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Go to Step 19

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Verify the proper brake system operation.

Does the original condition still exist?

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

System OK