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 park brake lever for proper operation by doing the following
steps:
- Turn the ignition ON.
- Press the park brake pedal until it stops. Verify the Brake Warning
Lamp is ON.
- Pull the park brake release lever. Verify the Brake Warning Lamp
is OFF.
Did the park brake warning lamp turn OFF and the pedal return to its
original height?
| --
|
Go to Step 4
|
Go to Step 3
|
3
|
- Inspect the park brake pedal assembly for interference, binding
or for broken components.
- Lubricate the park brake pedal assembly.
- If lubricating the park brake pedal assembly does not solve the
problem, replace the park brake pedal. Refer to
Park Brake Lever Assembly Replacement
in Park Brake.
Is the repair complete?
| --
|
Go to Step
33
| --
|
4
|
- Start the engine.
- Shift the vehicle into DRIVE.
- Attempt to move the vehicle by slowly pressing the accelerator
pedal.
Does the engine RPM increase without the vehicle moving?
| --
|
Go to Step 5
|
Go to Step 7
|
5
| Inspect the park brake cables for
corrosion, kinks, or interference with other components.
Are the park brake cables corroded, kinked, or interfering with other
components?
| --
|
Go to Step 6
|
Go to Step 7
|
6
| Realign
or replace the park brake cable(s). Refer to the appropriate procedure:
Is the repair complete?
| --
|
Go to Step
33
| --
|
7
|
- Remove the brake drum.
- Inspect the brake linings for the following conditions:
• | Contaminated lining material |
• | Incorrect lining material |
Refer to
Brake Shoe Inspection
in Drum Brakes.
Do any of the above conditions apply?
| --
|
Go to Step 8
|
Go to Step
9
|
8
| Replace the brake shoe linings. Refer to
Brake Shoe Replacement
in Drum Brakes.
Is the repair complete?
| --
|
Go to Step
9
|
Go to Step 10
|
9
| Inspect the brake shoe mounting hardware and springs for corrosion or
binding.
Is the mounting hardware or springs corroded or binding?
| -
|
Go to Step 10
|
Go to Step 11
|
10
| Replace the mounting hardware or
springs as necessary.
Is the repair complete?
| --
|
Go to Step
33
| --
|
11
| Inspect the park brake lever for corrosion and free movement without
binding.
Does the park brake lever move freely without binding?
| --
|
Go to Step 12
|
Go to Step 13
|
12
|
- Clean the park brake lever components and check for proper movement.
- If the park brake lever still does not move freely, replace the
park brake lever components.
Refer to
Park Brake Lever Assembly Replacement
in Park Brake.
Is the repair complete?
| --
|
Go to Step
33
| --
|
13
| Inspect the disc brake caliper mounting bolts for corrosion. Refer to
Brake Caliper Inspection
in Disc Brakes.
Are the sleeves or mounting bolts corroded?
| --
|
Go to Step 14
|
Go to Step
15
|
14
| Replace the mounting bolt sleeves and bolts as necessary.
Is the repair complete?
| --
|
Go to Step
33
| --
|
15
|
- Remove the caliper piston. Refer to the appropriate procedure:
- Inspect the caliper bore and the piston for the following conditions:
Is the piston or caliper bore damaged?
| --
|
Go to Step 16
|
Go to Step
17
|
16
| Replace the piston or the caliper as needed.
Is the repair complete?
| --
|
Go to Step
33
| --
|
17
|
- Inspect the brake pedal assembly for bent or misaligned components.
- Inspect the brake pedal for interference (binding) between the
pedal and the booster input rod.
Is the brake pedal binding?
| --
|
Go to Step
18
|
Go to Step 19
|
18
|
- Disassemble and realign or replace components as necessary.
- Replace the brake pedal. Refer to
Brake Pedal Replacement
.
Is the repair complete?
| --
|
Go to Step
33
| --
|
19
|
- Inspect the brake pedal for interference with other components.
- Inspect the brake pedal area for the following conditions:
• | Loose or misaligned the trim panels |
• | Loose components, wiring harnesses or aftermarket devices |
Are there any loose or interfering components?
| --
|
Go to Step 20
|
Go to Step
21
|
20
| Realign or reposition components as necessary.
Is the repair complete?
| --
|
Go to Step
33
| --
|
21
|
• | Inspect for collapsed, dented, or bent brake pipes. Refer to
Brake Fluid Leak
. |
Are the brake hoses or the brake pipes collapsed, bent, or kinked?
| --
|
Go to Step 22
|
Go to Step 23
|
22
| Reroute or replace the brake hoses
or the brake pipes as necessary. Refer to the appropriate procedure:
Is the repair complete?
| --
|
Go to Step
33
| --
|
23
|
- Remove the master cylinder reservoir cover.
- 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 24
|
Go to Step 25
|
24
|
- Install the master cylinder reservoir cover.
- Loosen the master cylinder mounting nuts 13 mm (1/2 in).
- Separate the master cylinder from the hydraulic brake booster.
- Apply the brake pedal 3 cm (1 in).
Does the booster output rod move?
| --
|
Go to Step
25
|
Go to Step 26
|
25
| Overhaul or replace the master cylinder. Refer to
Master Cylinder Overhaul
or
Master Cylinder Replacement
.
Is the repair complete?
| --
|
Go to Step
33
| --
|
26
| Replace the vacuum brake booster. Refer to
Power Vacuum Brake Booster Replacement
.
Is the repair complete?
| --
|
Go to Step
33
| --
|
27
|
- Remove the master cylinder reservoir cover.
- Inspect the brake fluid for contamination. Refer to
Brake Fluid and Brake Fluid Handling
.
Is the brake fluid contaminated?
| --
|
Go to Step
28
|
Go to Step 29
|
28
|
- Replace all rubber brake system components. Refer to the following
procedures:
- Flush the hydraulic brake system. Refer to
Hydraulic Brake System Flushing
.
Is the repair complete?
| --
|
Go to Step
33
| --
|
29
| Inspect the master cylinder outlet ports for restricted passages. Refer
to
Hydraulic Brake System Bleeding
.
Are the outlet ports restricted?
| --
|
Go to Step
30
|
Go to Step 31
|
30
|
- Overhaul the master cylinder. Refer to
Master Cylinder Overhaul
.
- Flush the hydraulic brake system. Refer to
Hydraulic Brake System Flushing
.
Is the repair complete?
| --
|
Go to Step
33
| --
|
31
| Inspect the brake pipes and the brake hoses for restricted passages.
Refer to
Hydraulic Brake System Flushing
.
Inspect 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 32
| System OK
|
32
|
- Determine the area of the restriction. This will involve the disassembly
of individual brake lines and checking for low fluid output.
- Flush the individual brake line or the brake hose.
- If the restriction cannot be removed, replace the brake hose or
the brake pipe as necessary. Refer to the appropriate procedure:
- Flush the hydraulic brake system. Refer to
Hydraulic Brake System Flushing
.
Is the repair complete?
| --
|
Go to Step
33
| --
|
33
| Verify proper brake system operation.
Does the brake system operate properly?
| --
| System OK
| Go to
Hydraulic Brake Diagnostic System Check
|