Was the Hydraulic Brake System Diagnostic Check performed?

-

Go to Step 2

Go to Hydraulic Brake Diagnostic System Check .

Check the park brake lever for proper operation by doing the following:

1. Turn the ignition ON.
2. Pull the park brake lever until it stops. Verify the Brake Warning Lamp is ON.
3. Release the park brake. 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

1. Check the park brake lever assembly for interference, binding or for broken components.
2. Lubricate the park brake lever assembly.
3. If lubricating the park brake lever assembly does not solve the problem, replace the park brake lever. Refer to Park Brake Lever Replacement in Park Brake.

Is the repair complete?

-

Go to Step 33

-

1. Start the engine.
2. Shift the vehicle into DRIVE.
3. 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

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

Realign or replace the park brake cable(s). Refer to Park Brake Cable Replacement (Front) or Park Brake Cable Replacement (Rear) in Park Brake.

Is the repair complete?

-

Go to Step 33

-

1. Remove the rear brake rotor.
2. Inspect the brake linings for the following:

•	Excessive wear

•	Uneven wear

•

Abuse

•

Glazing

•	Contaminated lining material

•	Incorrect lining material

Do any of the above conditions apply?

-

Go to Step 8

Go to Step 9

Replace the brake shoe linings. Refer to Brake Shoe Replacement in Park Brake.

Is the repair complete?

-

Go to Step 9

Go to Step 10

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

Replace the mounting hardware or springs as necessary.

Is the repair complete?

-

Go to Step 33

-

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

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 Shoe Replacement in Park Brakes.

Is the repair complete?

-

Go to Step 33

-

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

Replace the mounting bolt sleeves and bolts as necessary.

Is the repair complete?

-

Go to Step 33

-

1. Remove the caliper piston. Refer to Brake Caliper Overhaul in Disc Brakes.
2. Inspect the caliper bore and the piston for scoring, corrosion, plating damage or pitting.

Is there damage to the piston or caliper bore?

-

Go to Step 16

Go to Step 17

Replace the piston or the caliper as needed.

Is the repair complete?

-

Go to Step 33

-

1. Inspect the brake pedal assembly for bent or misaligned components.
2. 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

1. Disassemble and realign or replace components as necessary.
2. Replace the brake pedal. Refer to Brake Pedal Replacement.

Is the repair complete?

-

Go to Step 33

-

Check the brake pedal for interference with other components. Inspect the brake pedal area for the following:

Are there any loose or interfering components?

-

Go to Step 20

Go to Step 21

Realign or reposition components as necessary.

Is the repair complete?

-

Go to Step 33

-

Are the brake hoses or the brake pipes collapsed, bent, or kinked?

-

Go to Step 22

Go to Step 23

Reroute or replace the brake hoses or the brake pipes as necessary. Refer to Front Brake Hose Replacement or Pipe Replacement (Front), Rear Hose Replacement, Pipe Replacement (Rear).

Is the repair complete?

-

Go to Step 33

-

1. Remove the master cylinder reservoir cover.
2. 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

1. Install the master cylinder reservoir cover.
2. Loosen the master cylinder mounting nuts 13 mm (½ in).
3. Separate the master cylinder from the hydraulic brake booster.
4. Apply the brake pedal 3 cm (1 in).

Does the booster output rod move?

-

Go to Step 25

Go to Step 26

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

Is the repair complete?

-

Go to Step 33

-

Replace the hydraulic brake booster. Refer to Vacuum Brake Booster Replacement.

Is the repair complete?

-

Go to Step 33

-

1. Remove the master cylinder reservoir cover.
2. Inspect the brake fluid for contamination. Refer to Substandard or Contaminated Brake Fluid.

Is the brake fluid contaminated?

-

Go to Step 28

Go to Step 29

1. Replace all rubber brake system components. Refer to Master Cylinder Overhaul, Front Brake Hose Replacement or Rear Hose Replacement, Brake Caliper Overhaul.
2. Flush the hydraulic brake system. Refer to Flushing The Hydraulic Brake System.

Is the repair complete?

-

Go to Step 33

-

Check 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

1. Overhaul the master cylinder. Refer to Master Cylinder Overhaul.
2. Flush the hydraulic brake system. Refer to Flushing The Hydraulic Brake System.

Is the repair complete?

-

Go to Step 33

-

Check the brake pipes and the brake hoses for restricted passages. Refer to Flushing The Hydraulic Brake System.

Check for the following:

Do any of the above conditions apply?

-

Go to Step 33

System OK

1. Determine the area of the restriction. This will involve the disassembly of individual brake lines and checking for low fluid output.
2. Flush the individual brake line or the brake hose.
3. If the restriction cannot be removed, replace the brake hose or the brake pipe as necessary. Refer to Front Brake Hose Replacement or Pipe Replacement (Front), Rear Hose Replacement, Pipe Replacement (Rear).
4. Flush the hydraulic brake system. Refer to Flushing The Hydraulic Brake System.

Is the repair complete?

-

Go to Step 33

-

Verify proper brake system operation.

Does the original condition still exist?

-

Verify customer complaint. Begin the diagnosis again. Go to Step 1.

System OK