For 1990-2009 cars

Step | Action | Value(s) | Yes | No
--- | --- | --- | --- | ---
1 | Was the Hydraulic Brake Diagnostic System Check performed? | -- | Go to Step 2 | Go to Hydraulic Brake Diagnostic System Check
2 | Inspect the disc brake rotors for the following:

• | Hot spots

• | Scored rotor surface

• | Grooved rotor surface

Refer to Brake Rotor Lateral Runout Check in Disc Brakes.

Do any of the above conditions exist?

--

Go to Step 3

Go to Step 4

3 | Resurface or replace the brake rotor as necessary. Refer to Brake Rotor Refinishing or Brake Rotor Replacement in Disc Brakes. Is the repair complete? | -- | Go to Hydraulic Brake Diagnostic System Check | --
4 | Inspect the following brake caliper assembly components for corrosion:

• | Mounting bolts

• | Sleeves

• | Steering knuckle

• | Brake caliper

• | Brake caliper piston

Are any of the above components corroded or sticking?

--

Go to Step 5

Go to Step 6

5 | Repair or replace the brake calipers. Refer to Brake Caliper Overhaul or Brake Caliper Replacement in Disc Brakes. Is the repair complete? | -- | Go to Hydraulic Brake Diagnostic System Check | --
6 | 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 exist?

--

Go to Step 7

Go to Step 8

7 | Replace the brake linings as necessary. Refer to the applicable procedures.

• | Refer to Brake Pads Replacement in Disc Brakes.

• | Refer to Brake Shoe Replacement in Drum Brakes.

Is the repair complete?

--

Go to Hydraulic Brake Diagnostic System Check

--

8 | Inspect the brake assembly for loose, missing or broken components. Refer to Brake Pad Inspection in Disc Brakes and Brake Shoe Inspection in Drum Brakes. Are there missing or loose brake assembly components? | -- | Go to Step 9 | Go to Step 10
9 | Repair or replace the components as necessary. Is the repair complete? | -- | Go to Hydraulic Brake Diagnostic System Check | --
10 | Inspect the hydraulic brake system for leaks. Are there brake fluid leaks? | -- | Go to Step 11 | Go to Step 13
11 |

1. Tighten the brake hose or pipe fittings to 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?

--

Go to Step 12

Go to Hydraulic Brake Diagnostic System Check

12 | Replace the brake hose or pipe as necessary. Has the repair been performed? | -- | Go to Hydraulic Brake Diagnostic System Check | --
13 | Inspect the brake caliper piston seal for leaks. Is the brake caliper piston seal leaking? | -- | Go to Step 14 | Go to Step 15
14 | Replace the brake caliper piston seal. Refer to Brake Caliper Overhaul in Disc Brakes. Is the repair complete? | -- | Go to Hydraulic Brake Diagnostic System Check | --
15 | Inspect the park brake for improper adjustment. Is the park brake improperly adjusted? | -- | Go to Step 16 | Go to Step 17
16 | Adjust or replace the park brake cable. Refer to Park Brake Cable Service/Adjustment in Park Brake. Is the repair complete? | -- | Go to Hydraulic Brake Diagnostic System Check | --
17 | Inspect for an internal leak within the master cylinder. Refer to Master Cylinder Diagnosis . Is there an internal leak within the master cylinder? | -- | Go to Step 18 | Go to Step 19
18 | Replace the master cylinder. Refer to Brake Modulator/Master Cylinder Assembly Replacement in Antilock Brake System. Is the repair complete? | -- | Go to Hydraulic Brake Diagnostic System Check | --
19 | Inspect for contaminated or improper brake fluid. Is the brake fluid contaminated or improper? | -- | Go to Step 20 | Go to Step 21
20 | Replace all of the hydraulic brake system rubber components.

1. Flush the hydraulic brake system. Refer to Hydraulic Brake System Flushing .
2. Replace the ABS modulator. Refer to Brake Modulator/Master Cylinder Assembly Replacement in Antilock Brake System.
3. Repair or replace the master cylinder. Refer to Master Cylinder Overhaul .
4. Replace the TCS modulator. Refer to Traction Control System Modulator/Motor Pack Replacement in Antilock Brake System (if equipped).
5. Replace the front brake hoses. Refer to Front Brake Hose Replacement .
6. Replace the rear brake hoses. Refer to Rear Brake Hose Replacement .
7. Repair or replace the brake calipers. Refer to Brake Caliper Overhaul or Brake Caliper Replacement in Disc Brakes.
8. Repair or replace the wheel cylinders. Refer to Wheel Cylinder Overhaul or Wheel Cylinder Replacement in Drum Brakes.
9. Flush the hydraulic brake system. Refer to Hydraulic Brake System Flushing .

Is the repair complete?

--

Go to Hydraulic Brake Diagnostic System Check

--

21 | Inspect the brake pipes and hoses for a restricted brake fluid passage. Check for the following:

• | Low fluid or no fluid output

• | Spurting of fluid while pressing the brake pedal

• | Particles suspended in the fluid

Refer to Hydraulic Brake System Bleeding .

Is there a restricted brake fluid passage?

--

Go to Step 22

Go to Step 23

22 |

1. Determine the area of the restriction. This will involve the disassembly of individual brake lines and checking for low or no fluid output
2. Flush the individual brake line or hose. Refer to Hydraulic Brake System Flushing .
3. If the restriction cannot be removed, replace the applicable brake hose or the brake pipe.
4. Flush the hydraulic brake system. Refer to Hydraulic Brake System Flushing .

Is the repair complete?

--

Go to Hydraulic Brake Diagnostic System Check

--

23 | Inspect for air in the brake system. Refer to Hydraulic Brake System Bleeding . Is there air in the brake system? | -- | Go to Step 24 | Go to Step 25
24 | Bleed the brake system. Refer to Hydraulic Brake System Bleeding . Is the repair complete? | -- | Go to Hydraulic Brake Diagnostic System Check | --
25 | Verify proper brake system operation. Does the original condition still exist? | -- | Go to Step 1 | --