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 vehicle for overloading.

Refer to Loading Your Vehicle in the Vehicle Owner's Manual.

Is there excessive vehicle weight?

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Go to Step 3

Go to Step 4

Remove the extra weight from the vehicle.

Has the excessive weight been removed?

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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 and Brake Shoe Inspection in Drum Brakes.

Do any of the above conditions apply?

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Go to Step 5

Go to Step 6

Replace the brake linings. Refer to the appropriate procedure in Disc or Drum Brakes from the following list:

Is the repair complete?

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Go to Step 29

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Inspect the brake rotor surface for excessive thickness variation. Refer to Brake Rotor Thickness Variation Check in Disc Brakes.

Is the rotor thickness variation beyond specification?

0.010 mm (0.003 in)

Go to Step 7

Go to Step 8

1. Resurface 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 (Refinished) thickness, replace the rotor. Refer to Brake Rotor Replacement in Disc Brakes.

Refer to Component Specifications in Disc Brakes.

Is the repair complete?

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Go to Step 29

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Inspect the brake rotors for excessive lateral runout. Refer to Brake Rotor Lateral Runout Check .

Is the brake rotor runout excessive?

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Go to Step 9

Go to Step 10

1. Refsurface 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 (Refinished) thickness, replace the rotor. Refer to Brake Rotor Replacement in Disc Brakes.

Refer to Component Specifications in Disc Brakes.

Is the repair complete?

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Go to Step 29

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Inspect brake assembly for missing or loose attachments. Refer to Brake Pad Inspection in Disc Brakes or to Brake Shoe Inspection in Drum Brakes.

Are there missing attachments?

--

Go to Step 11

Go to Step 12

Tighten the attachments.

Is the repair complete?

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Go to Step 29

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1. Remove the brake drum. Refer to Brake Drum Replacement in Drum Brakes.
2. Inspect the drum brakes for improper adjustment. Refer to Drum Brake Adjustment in Drum Brakes.

Are the brakes improperly adjusted?

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Go to Step 13

Go to Step 14

Adjust the drum brakes properly. Refer to Drum Brake Adjustment in Drum Brakes.

Is the repair complete?

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Go to Step 29

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Inspect the master cylinder for leakage. Refer to Master Cylinder Diagnosis .

Is the master cylinder leaking?

--

Go to Step 15

Go to Step 16

Overhaul the master cylinder. Refer to Master Cylinder Overhaul .

Is the repair complete?

-

Go to Step 29

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Inspect the hydraulic brake system for leaks.

Refer to Brake Fluid Leak and Brake Hose and Pipe Diagnosis .

Is there any sign of leakage?

--

Go to Step 17

Go to Step 19

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 18

Go to Step 19

Replace the brake hose or pipe as necessary. Refer to the appropriate procedure from the following list:

Is the repair complete?

--

Go to Step 29

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Inspect the brake system for air. Refer to Hydraulic Brake System Bleeding .

Is there air in the system?

--

Go to Step 20

Go to Step 21

Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding .

Is the repair complete?

--

Go to Step 29

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Inspect the brake fluid for contamination. Refer to Brake Fluid and Brake Fluid Handling .

Is the brake fluid contaminated?

--

Go to Step 22

Go to Step 23

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

Is the repair complete?

--

Go to Step 29

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1. Remove the brake drum. Refer to Brake Drum Replacement in Drum Brakes.
2. Inspect the wheel cylinder for leakage.

Does the wheel cylinder show signs of leakage?

--

Go to Step 24

Go to Step 25

Overhaul or replace the wheel cylinder. Refer to the appropriate procedure in Drum Brakes from the following list:

Is the repair complete?

--

Go to Step 29

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Inspect the rear axle oil seal for leakage.

Is the seal leaking?

--

Go to Step 26

Go to Step 27

Replace the rear axle oil seal.

Is the repair complete?

--

Go to Step 29

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1. Remove the brake caliper. Refer to Brake Caliper Replacement .
2. Inspect the brake caliper for leakage. Refer to Brake Caliper Inspection .

Does the brake caliper show signs of leakage?

--

Go to Step 28

Go to Hydraulic Brake Diagnostic System Check

Overhaul the brake caliper. Refer to the appropriate procedure in Disc Brakes from the following list:

Is the repair complete?

--

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