GM Service Manual Online
For 1990-2009 cars only

Step

Action

Value(s)

Yes

No

1

Was the Hydraulic Brake System Diagnostic Check performed?

--

Go to Step 2

Go to Hydraulic Brake Diagnostic System Check

2

Inspect the hydraulic brake system for leaks. Refer to Brake Hose and Pipe Diagnosis .

Are there any leaks?

--

Go to Step 3

Go to Step 4

3

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

Is the repair complete?

--

Go to Step 28

--

4

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

    • Excessive wear
    • Uneven wear
    • Abuse
    • Glazing
    • Contaminated lining material
    • Incorrect lining material

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

Do any of the above conditions apply?

--

Go to Step 5

Go to Step 6

5

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

Is the repair complete?

--

Go to Step 28

--

6

Inspect the following brake caliper assembly components for corrosion:

    • Mounting bolts
    • Sleeves
    • Steering knuckle
    • Brake caliper
    • Brake caliper piston

Refer to Brake Caliper Inspection in Disc Brakes.

Are any of the above components corroded or sticking?

--

Go to Step 7

Go to Step 8

7

Replace the corroded components. Refer to Brake Caliper Overhaul or Brake Caliper Replacement in Disc Brakes.

Is the repair complete?

--

Go to Step 28

--

8

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

Are there loose, missing or broken brake assembly components?

--

Go to Step 9

Go to Step 10

9

Tighten or replace the components as necessary.

Is the repair complete?

--

Go to Step 28

--

10

  1. Inspect the wheel cylinder for leakage.
  2. Inspect the wheel cylinder for binding.

Is the wheel cylinder leaking or binding?

--

Go to Step 11

Go to Step 12

11

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

Is the repair complete?

--

Go to Step 28

--

12

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

Is the brake pedal binding?

--

Go to Step 13

Go to Step 14

13

Disassemble and realign or replace components as necessary.

Is the repair complete?

--

Go to Step 28

--

14

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

    • loose or misaligned the trim panels
    • loose components, wiring harnesses or aftermarket devices

Are there any loose or interfering components?

--

Go to Step 15

Go to Step 16

15

Realign or reposition components as necessary.

Is the repair complete?

--

Go to Step 28

--

16

    • Check for collapsed , dented, or bent brake pipes.
    • Check the brake hoses for sharp kinks. Refer to Brake Hose and Pipe Diagnosis .

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

--

Go to Step 17

Go to Step 18

17

Reroute or replace the brake hoses or pipes as necessary. Refer to:

Is the repair complete?

--

Go to Step 28

--

18

  1. Remove the master cylinder reservoir cover.
  2. Rapidly apply the brake pedal 3 cm (1 in), observing the brake fluid in the reservoir.

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

--

Go to Step 19

Go to Step 20

19

  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?

--

Go to Step 20

Go to Step 21

20

Replace the master cylinder. Refer to Master Cylinder Replacement .

Is the repair complete?

--

Go to Step 28

--

21

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

Is the repair complete?

--

Go to Step 28

--

22

  1. Remove the master cylinder reservoir cover.
  2. Inspect the brake fluid for contamination. Refer to Brake Fluid and Brake Fluid Handling .

Is the brake fluid contaminated?

--

Go to Step 23

Go to Step 24

23

  1. Replace all rubber brake system components. Refer to:
  2. •  Wheel Cylinder Overhaul in Drum Brakes
    •  Brake Caliper Overhaul in Disc Brakes
  3. Flush the hydraulic brake system. Refer to Hydraulic Brake System Flushing .

Is the repair complete?

--

Go to Step 28

--

24

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

Are the outlet ports restricted?

--

Go to Step 25

Go to Step 26

25

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

Is the repair complete?

--

Go to Step 28

--

26

Check the brake pipes and the brake hoses for restricted passages. Refer to Hydraulic Brake System Flushing .

Check for the following:

    • low fluid or no fluid output
    • spurting of fluid while pressing the brake pedal
    • particles suspended in the fluid

Do any of the above conditions apply?

--

Go to Step 28

System OK

27

  1. Determine the area of the restriction. This will involve the disassembly of individual brake lines and checking 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. Refer to:
  4. Flush the hydraulic brake system. Refer to Hydraulic Brake System Flushing .

Is the repair complete?

--

Go to Step 28

--

28

Verify proper brake system operation.

Does the original condition still exist?

--

Go to Step 1

System OK