For 1990-2009 cars

Step | Action | Value(s) | Yes | No
--- | --- | --- | --- | ---
1 | Did you perform the Hydraulic Brake Diagnostic System Check? | -- | Go to Step 2 | Go to Hydraulic Brake Diagnostic System Check
2 | Inspect the vehicle for overloading. Refer to Loading Your Vehicle in the Vehicle Owner's Manual. Is there excessive vehicle weight? | -- | Go to Step 3 | Go to Step 4
3 | Remove the extra weight from the vehicle. Has the excessive weight been removed? | -- | Go to Hydraulic Brake Diagnostic System Check | --
4 | Inspect the disc brake pads and brake shoe linings for the following conditions:

• | Excessive wear

• | Uneven wear

• | Abuse

• | Contaminated lining material

• | Incorrect lining material

Refer to Brake Pad Inspection in Disc Brakes and Brake Shoe Inspection in Drum Brakes.

Did you find a condition?

--

Go to Step 5

Go to Step 6

5 | Replace the brake linings. Refer to the following procedures:

• | Front Disc Brake Pads Replacement in Disc Brakes

• | Rear Disc Brake Pads Replacement in Disc Brakes

• | Brake Shoe Replacement in Drum Brakes

Did you complete the repair?

--

Go to Hydraulic Brake Diagnostic System Check

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6 | 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? | 0.013 mm (0.005 in) | Go to Step 7 | Go to Step 8
7 |

1. Resurface the brake rotor. Refer to Brake Rotor Refinishing in Disc Brakes.
2. If refinishing the brake rotor results in a thickness that is less than the thinnest (refinished) thickness, replace the rotor. Refer to the following procedures:

• | Front Brake Rotor Replacement in Disc Brakes

• | Rear Brake Rotor Replacement in Disc Brakes

• | Brake Drum Replacement in Drum Brakes

Did you complete the repair?

--

Go to Hydraulic Brake Diagnostic System Check

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8 | Inspect the brake rotors for excessive lateral runout. Refer to Brake Rotor Lateral Runout Check . Is the brake rotor runout excessive? | -- | Go to Step 9 | Go to Step 10
9 |

1. Resurface the brake rotor. Refer to Brake Rotor Refinishing in Disc Brakes or Brake Drum Refinishing in Drum Brakes.
2. If refinishing the brake rotors or drums results in a thickness that is less than the thinnest (refinished) thickness, replace the rotor or drum. Refer to the following procedures:

• | Front Brake Rotor Replacement in Disc Brakes

• | Rear Brake Rotor Replacement in Disc Brakes

• | Brake Drum Replacement in Drum Brakes

Did you complete the repair?

--

Go to Hydraulic Brake Diagnostic System Check

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10 | Inspect brake assembly for missing or loose attachments. Refer to Brake Pad Inspection in Disc Brakes or Brake Shoe Inspection in Drum Brakes. Are there missing attachments? | -- | Go to Step 11 | Go to Step 12
11 | Tighten or replace the attachments. Did you complete the repair? | -- | Go to Hydraulic Brake Diagnostic System Check | --
12 |

1. Remove the brake drum. Refer to Brake Drum 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?

--

Go to Step 13

Go to Step 14

13 | Adjust the drum brakes properly. Refer to Drum Brake Adjustment in Drum Brakes. Did you complete the repair? | -- | Go to Hydraulic Brake Diagnostic System Check | --
14 | Inspect the master cylinder for leakage. Refer to Master Cylinder Diagnosis . Is the master cylinder leaking? | -- | Go to Step 15 | Go to Step 16
15 | Replace the master cylinder. Refer to Master Cylinder Replacement . Did you complete the repair? | - | Go to Hydraulic Brake Diagnostic System Check | --
16 | Inspect the hydraulic brake system for leaks. Is there any sign of leakage? | -- | Go to Step 17 | Go to Step 19
17 |

1. Tighten the 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.

Does a leak still exist?

--

Go to Step 18

Go to Step 19

18 | Replace the brake hose or pipe as necessary. Refer to the following procedures:

• | Front Brake Hose Replacement

• | Rear Brake Hose Replacement

• | ISO Flares Replacement

Did you complete the repair?

--

Go to Hydraulic Brake Diagnostic System Check

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19 | Inspect the brake system for air. Refer to Hydraulic Brake System Bleeding . Is there air in the system? | -- | Go to Step 20 | Go to Step 21
20 | Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding . Did you complete the repair? | -- | Go to Hydraulic Brake Diagnostic System Check | --
21 | Inspect the brake fluid for contamination. Is the brake fluid contaminated? | -- | Go to Step 22 | Go to Step 23
22 |

1. Replace all rubber brake system components. Refer to the following procedures:

• | Master Cylinder Replacement in Disc Brakes

• | Front Brake Hose Replacement in Disc Brakes

• | Rear Brake Hose Replacement in Disc Brakes

• | Front Brake Caliper Replacement in Disc Brakes

• | Rear Brake Caliper Replacement in Disc Brakes

• | Wheel Cylinder Overhaul in Drum Brakes

• | Proportioning Valve Replacement

• | Brake Pressure Modulator Valve Assembly Replacement in Antilock Brake System

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

Did you complete the repair?

--

Go to Hydraulic Brake Diagnostic System Check

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23 |

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

Does the wheel cylinder show signs of leakage?

--

Go to Step 24

Go to Step 25

24 | Overhaul or replace the wheel cylinder. Refer to Wheel Cylinder Overhaul or Wheel Cylinder Replacement in Drum Brakes. Did you complete the repair? | -- | Go to Hydraulic Brake Diagnostic System Check | --
25 |

1. Remove the brake caliper. Refer to Front Brake Caliper Replacement or Rear Brake Caliper Replacement in Disc Brakes.
2. Inspect the brake caliper for leakage.

Does the brake caliper show signs of leakage?

--

Go to Step 26

Go to Step 27

26 | Overhaul the brake caliper. Refer to Front Brake Caliper Overhaul or Rear Brake Caliper Overhaul in Disc Brakes. Did you complete the repair? | -- | Go to Hydraulic Brake Diagnostic System Check | --
27 | Verify proper brake system operation. Does the original condition still exist? | -- | Go to Step 1 | System OK