Tools Required

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

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 OFF the engine.
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. Refer to the appropriate procedure from the following list:

Is the repair complete?

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Go to Step 29

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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 6

Go to Step 7

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

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 from the following list:

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

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 in Drum Brakes from the following list:

Is the repair complete?

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Go to Step 29

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

Is the wheel cylinder leaking or binding?

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Go to Step 12

Go to Step 13

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

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 interference (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

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

Is the repair complete?

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Go to Step 29

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

Are there any loose or interferring components?

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Go to Step 16

Go to Step 17

Realign or reposition components as necessary.

Is the repair complete?

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Go to Step 29

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

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Go to Step 18

Go to Step 19

Reroute or replace the brake hoses or pipes as necessary. Refer to the appropriate procedure from the following list:

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), observing 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 hydraulic brake booster. Refer to Power Brake Booster Replacement .

Is the repair complete?

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Go to Step 29

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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?

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Go to Step 24

Go to Step 25

1. Replace all rubber brake system components. Refer to the appropriate procedure from the following list:

•	Master Cylinder Overhaul

•	Front Brake Hose Replacement

•	Brake Pipe Replacement

•	Hydraulic Brake System Bleeding

•	Wheel Cylinder Replacement

•	Brake Caliper Overhaul

2. 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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Check 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 Flushing .

Is the repair complete?

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Go to Step 29

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

Check for the following:

Do any of the above conditions apply?

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Go to Step 29

Go to Hydraulic Brake Diagnostic System Check

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 the appropriate procedure from the following list:

•	Front Brake Hose Replacement

•	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 29

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Verify proper brake system operation.

Does the original condition still exist?

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Go to Step 1

Go to Hydraulic Brake Diagnostic System Check