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 disc brake rotors for the following conditions:

• | Hot spots

• | Scored rotor surface

• | Grooved rotor surface

Refer to Brake Rotor Lateral Runout Check in Disc Brakes.

Did you find a condition?

--

Go to Step 3

Go to Step 4

3 |

1. Refinish 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 (Refinishing) thickness, replace the rotor. Refer to Front Brake Rotor Replacement or Rear Brake Rotor Replacement in Disc Brakes.

Did you complete the repair?

--

Go to Hydraulic Brake Diagnostic System Check .

--

4 | Inspect the following brake caliper assembly components for corrosion:

• | The mounting bolts

• | The guide pins

• | The steering knuckle

• | The Brake caliper and bracket

• | The 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 calipers. Refer to the following procedures:

• | Front Brake Caliper Overhaul in Disc Brakes

• | Rear Brake Caliper Overhaul in Disc Brakes

• | Front Brake Caliper Replacement in Disc Brakes

• | Rear Brake Caliper Replacement in Disc Brakes

Did you complete the repair?

--

Go to Hydraulic Brake Diagnostic System Check .

--

6 | Inspect the disc brake pads and brake shoe linings for the following conditions:

• | Excessive wear

• | Uneven wear

• | Abuse

• | Glazing

• | Contaminated lining material

• | Incorrect lining material

Did you find a condition?

--

Go to Step 7

Go to Step 8

7 | 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 .

--

8 | Inspect the brake assembly for loose, missing or broken components. Refer to Brake Pad Inspection in Disc Brakes or Brake Shoe Inspection in Drum Brakes. Are there missing or loose brake assembly components? | -- | Go to Step 9 | Go to Step 10
9 | Tighten or replace loose or missing brake assembly components. 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 .

--

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. 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 the leak still exist?

--

Go to Step 12

Go to Hydraulic Brake Diagnostic System Check .

12 | 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 .

--

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 Front Brake Caliper Overhaul or Rear Brake Caliper Overhaul in Disc Brakes. Did you complete the repair? | -- | 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. Did you complete the repair? | -- | 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 Master Cylinder Replacement in Hydraulic Brakes. Did you complete the repair? | -- | 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 | Flush the brake system. Refer to Hydraulic Brake System Flushing . Did you complete the repair? | -- | Go to Hydraulic Brake Diagnostic System Check . | --
21 | Inspect the brake pipes and hoses for a restricted brake fluid passage. Inspect for the following conditions:

• | 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 inspecting 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 brake line or hose as necessary. Refer to the following procedures:

• | Front Brake Hose Replacement

• | Rear Brake Hose Replacement

• | ISO Flares Replacement

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

Did you complete the repair?

--

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 . Did you complete the repair? | -- | Go to Hydraulic Brake Diagnostic System Check . | --
25 | Verify proper brake system operation. Does the original condition still exist? | -- | Go to Step 1 | --