Was the Hydraulic Brake Diagnostic System Check performed?

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Go to Step 2

Go to Brake System Diagnosis

Has the operator been advised of improper braking procedures by riding the brake pedal?

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Go to Step 3

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Inspect the vehicle for overloading.

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. Refinish 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 thinnest (Refinishing) thickness, replace the rotor. Refer to Component Specifications in Drum Brakes or Brake Rotor Replacement in Disc Brakes.

Is the repair complete?

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Go to Step 19

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Inspect the vehicle brake booster for the following:

Refer to Vacuum Booster Diagnosis or Hydraulic Booster Noise Diagnosis .

Do any of the above conditions apply?

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Go to Step 12

Go to Step 13

Repair or replace the brake booster. Refer to Power Vacuum Brake Booster Replacement or Power Brake Booster Replacement in Hydraulic Brakes.

Is the repair complete?

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Go to Step 19

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Inspect the vehicle for a leaking master cylinder (internal). Refer to Master Cylinder Diagnosis in Hydraulic Brakes.

Is the master cylinder leaking?

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Go to Step 14

Go to Step 15

Overhaul or replace the master cylinder. Refer to Master Cylinder Replacement or Master Cylinder Overhaul .

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 .

Are any of the above components leaking?

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Go to Step 16

Go to Step 17

Repair the cause of the leak.

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.
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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Go to Step 20

Go to Brake System Diagnosis

Verify customer concern.

Has the customer concern been verified?

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Go to Step 1

Go to Brake System Diagnosis