Did you perform the Hydraulic Brake System Diagnostic Check?

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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 26

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

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 appropriate procedure:

Is the repair complete?

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Go to Step 26

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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?

Disc:

0.010 mm

(0.003 in)

Drums:

0.15 mm

(0.006 in)

Go to Step 8

Go to Step 7

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

Is the brake rotor runout excessive?

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Go to Step 8

Go to Step 9

1. Resurface the brake rotor. Refer to Brake Rotor Refinishing in Disc Brakes.
2. Inspect 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 (Refinished) thickness, replace the rotor. Refer to Front Brake Rotor Replacement or Rear Brake Rotor Replacement in Disc Brakes.

Is the repair complete?

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Go to Step 26

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Inspect brake assembly for missing or loose attachments.

Are any attachments missing?

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Go to Step 10

Go to Step 11

Replace or tighten the attachments. Refer to the appropriate procedure:

Is the repair complete?

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Go to Step 26

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1. Remove the brake drum. Refer to Brake Shoe 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 12

Go to Step 13

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

Is the repair complete?

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Go to Step 26

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

Is the master cylinder leaking?

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Go to Step 14

Go to Step 15

Overhaul the master cylinder. Refer to Master Cylinder Overhaul .

Is the repair complete?

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Go to Step 26

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Inspect the hydraulic brake system for leaks.

Refer to Brake Fluid Leak .

Is there any sign of leakage?

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Go to Step 16

Go to Step 18

1. Tighten the loose 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 17

Go to Step 18

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

Is the repair complete?

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Go to Step 26

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

Is there air in the system?

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Go to Step 19

Go to Step 20

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

Is the repair complete?

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Go to Step 26

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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 21

Go to Step 22

1. Replace all rubber brake system components. Refer to:

•	Master Cylinder Overhaul

•	Front Brake Hose Replacement

•	Rear Brake Hose Replacement

•	Wheel Cylinder Overhaul in Drum Brakes.

•	Front Brake Caliper Overhaul in Disc Brakes.

•	Rear Brake Caliper Overhaul in Disc Brakes.

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

Is the repair complete?

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Go to Step 26

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

Does the wheel cylinder show signs of leakage?

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Go to Step 23

Go to Step 24

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

Is the repair complete?

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Go to Step 26

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1. Remove the brake caliper. Refer to the appropriate procedure:

•	Front Brake Caliper Replacement in Disc Brakes

•	Rear Brake Caliper Replacement in Disc Brakes

2. Inspect the brake caliper for leakage. Refer to Brake Caliper Inspection in Disc Brakes

Is the brake caliper leaking?

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Go to Step 25

Go to Step 26

Overhaul the brake caliper. Refer to the appropriate procedure:

Is the repair complete?

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Go to Step 26

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Verify proper brake system operation.

Does the brake system operate properly?

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System OK

Go to Hydraulic Brake Diagnostic System Check