Step
| Action
| Yes
| No
|
DEFINITION: This diagnostic table is designed to diagnose ONLY the components
of the HYDRAULIC brake system in order to determine if the HYDRAULIC brake system
is operating properly. You will be directed by the appropriate Symptom table to
go to other brake system diagnostic tables as appropriate.
|
1
| Were you sent here from a Brake Symptom table?
| Go to
Step 2
| Go to
Diagnostic Starting Point - Hydraulic Brakes
|
2
| Inspect and adjust the brake fluid level in the brake master cylinder. Refer
to
Master Cylinder Reservoir Filling
.
Was the brake fluid level low?
| Go to
Step 3
| Go to
Step 4
|
3
|
- Inspect the brake fluid for the following conditions, indicating brake
fluid contamination:
| • | Fluid separation, indicating two types of fluid are present |
| - | Swirled appearance - oil-based substance |
| - | Layered appearance - silicone-based substance |
| - | Cloudy appearance - moisture |
| - | Dark appearance/ suspended particles in fluid - dirt, rust, corrosion,
brake dust |
- Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master
cylinder grommets for swelling, indicating fluid contamination.
Do any of the above conditions exist?
| Go to
Step 5
| Go to
Step 6
|
4
|
- Inspect the brake fluid for the following conditions, indicating brake
fluid contamination:
| • | Fluid separation, indicating two types of fluid are present |
| - | Swirled appearance - oil-based substance |
| - | Layered appearance - silicone-based substance |
| - | Cloudy appearance - moisture |
| - | Dark appearance/ suspended particles in fluid - dirt, rust, corrosion,
brake dust |
- Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master
cylinder grommets for swelling, indicating fluid contamination.
Do any of the above conditions exist?
| Go to
Step 5
| Go to
Step 12
|
5
|
- Flush the hydraulic brake system. Refer to
Hydraulic Brake System Flushing
.
- If the brake fluid WAS contaminated with an oil-based or a silicone-based
fluid, indicated by fluid separation and/or a swollen master cylinder reservoir
cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform
the following steps. Refer to the procedures indicated.
| 2.1. | Remove ALL of the following components listed. Each component contains
internal rubber seals/linings which have been contaminated. |
| 2.2. | Clean out the hydraulic brake pipes using denatured alcohol, or equivalent. |
| 2.3. | Dry the brake pipes using non-lubricated, filtered air. |
| 2.4. | Repair or replace ALL of the following components listed. Each component
contains internal rubber seals/linings which have been contaminated. |
| • | Brake master cylinder reservoir: Clean the brake master cylinder reservoir
using denatured alcohol, or equivalent, then dry the reservoir using non-lubricated,
filtered air, or if necessary, replace the brake master cylinder reservoir. |
| • | Replace the brake master cylinder reservoir cap diaphragm. |
- If the brake fluid was NOT contaminated with an oil-based fluid, but
WAS contaminated with water or dirt, rust, corrosion, and/or brake dust, replace
the brake master cylinder reservoir cap diaphragm which may have allowed moisture
or dirt to enter the system.
- Refill and bleed the hydraulic brake system. Refer to
Hydraulic Brake System Bleeding
.
Did you complete the operation and any required repairs and/or replacements?
| Go to
Step 9
| --
|
6
|
- Inspect the following hydraulic brake system components for external
fluid leaks. Repair or replace any of the components found to be leaking brake
fluid. Refer to the appropriate procedures:
| • | Brake master cylinder
reservoir cap diaphragm |
- If you repaired or replaced any of the brake system components listed,
bleed the hydraulic brake system. Refer to
Hydraulic Brake System Bleeding
. While bleeding the hydraulic brake system, observe
for the following conditions:
| • | The presence of air in the system at a bleeder valve location other
than at the repair location, except if the brake master cylinder and/or the proportioning
valve assembly, was replaced |
| • | An unrestricted and even flow of brake fluid per axle during the bleeding
procedure |
Did you find and correct a condition?
| Go to
Step 7
| Go to
Step 12
|
7
| Was there air in the system at a bleeder valve location other than at the
repair location, except if the brake master cylinder was replaced?
| Go to
Step 19
| Go to
Step 8
|
8
| Was the flow of brake fluid unrestricted and even per axle during the bleeding
procedure?
| Go to
Step 9
| Go to
Step 10
|
9
| Inspect the hydraulic function of the brake calipers/wheel cylinders for
proper operation. Refer to
Hydraulic Brake Component Operation Visual Inspection
.
Was the hydraulic function of the brake calipers/wheel cylinders operating
properly?
| Go to
Step 21
| Go to
Step 14
|
10
| Was the flow of brake fluid restricted or uneven through front axle hydraulic
components during the bleeding procedure?
| Go to
Step 13
| Go to
Step 11
|
11
| Was the flow of brake fluid restricted or uneven through rear axle hydraulic
components during the bleeding procedure?
| Go to
Step 17
| --
|
12
| Inspect the hydraulic function of the brake calipers/wheel cylinders for
proper operation. Refer to
Hydraulic Brake Component Operation Visual Inspection
.
Was the hydraulic function of the brake calipers/wheel cylinders operating
properly?
| Go to
Step 15
| Go to
Step 13
|
13
| Determine if the brake caliper is restricting the flow of brake fluid and/or
not operating properly:
- Raise and support the vehicle. Refer to
Lifting and Jacking the Vehicle
in General Information.
- Remove the tire and wheel assemblies. Refer to
Tire and Wheel Removal and Installation
in Tires and Wheels.
- Open the suspected caliper bleeder valve.
- Using a large C-clamp, compress the caliper piston and observe for an
unrestricted flow of brake fluid and for free movement of the caliper piston.
- Close the caliper bleeder valve.
Was the flow of brake fluid unrestricted and did the caliper piston move
freely?
| Go to
Step 17
| Go to
Step 14
|
14
| Repair or replace any brake caliper/wheel cylinder that was not operating
properly. Refer to the appropriate procedure.
Did you complete the repair and/or replacement?
| Go to
Step 21
| --
|
15
| Bleed the hydraulic brake system to observe for the presence of air in the
system and to observe for an unrestricted and even flow of brake fluid per axle
during the bleeding procedure. Refer to
Hydraulic Brake System Bleeding
.
Was there air in the system?
| Go to
Step 19
| Go to
Step 16
|
16
| Was the flow of brake fluid unrestricted and even per axle during the bleeding
procedure?
| Go to
Step 21
| Go to
Step 17
|
17
|
- Inspect the hydraulic brake pipes and flexible brake hoses for signs
of a fluid restriction; such as being bent, kinked, pinched or damaged. Refer
to
Brake Pipe and Hose Inspection
.
- Replace any of the hydraulic brake pipes and/or flexible brake hoses
found to be bent, kinked, pinched, or damaged. Refer to the following procedures
as necessary:
- If none of the hydraulic brake pipes or flexible brake hoses were visibly
bent, kinked, pinched, or damaged, replace the hydraulic brake flex hose at the
restricted location.
Did you find and correct a condition?
| Go to
Step 21
| Go to
Step 18
|
18
|
- If equipped with a proportioning valve assembly, replace the valve assembly.
Refer to
Proportioning Valve Replacement
.
- If equipped with Antilock Brakes, replace the brake pressure modulator
valve (BPMV), in order to correct the hydraulic brake dynamic rear proportioning
mechanical operation. Refer to
Brake Pressure Modulator Valve Replacement
in Antilock Brake System.
Did you complete the replacement?
| Go to
Step 21
| --
|
19
|
- Inspect the hydraulic brake system components for brake fluid seepage
at a seal and/or fitting location, which may have drawn air into the system.
- Inspect the hydraulic brake system components for evidence of a recent
repair, which may have introduced air into the system.
- Repair or replace any of the components found to be installed incorrectly
or seeping brake fluid.
Did you find and correct a condition?
| Go to
Step 21
| Go to
Step 20
|
20
|
- Inspect the brake master cylinder for internal fluid leaks. Refer to
Brake System Internal Leak Test
.
- Repair or replace the brake master cylinder if it is found to be leaking
brake fluid internally. Refer to
Master Cylinder Overhaul
or
Master Cylinder Replacement
.
Did you find and correct a condition?
| Go to
Step 21
| Return to Symptom Table
|
21
| Install or connect components that were removed or disconnected during diagnosis.
Did you complete the operation?
| Hydraulic Brake System OK
Return to Symptom Table
| --
|
