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 the Hydraulic Brake Diagnostic System Check
2 | Perform the brake pedal travel measurement procedure. Refer to Brake Pedal Travel Gradually Increases . Does the brake pedal travel exceed the specified measurement? | -- | Go to Step 3 | System OK
3 | Inspect the brake linings for the following:

• | Excessive wear

• | Contaminated lining material

• | Uneven wear

• | Glazing

• | Abuse

• | Incorrect lining material

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

Do any of the above conditions exist?

--

Go to Step 4

Go to Step 5

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

• | Front Disc Brake Pads Replacement in Disc Brakes.

• | Rear Disc Brake Pads Replacement in Disc Brakes.

• | Brake Shoe Replacement in Drum Brakes.

Is the repair complete?

--

Go to the Hydraulic Brake Diagnostic System Check

--

5 | Inspect the brake rotors for the following:

• | Hot spots

• | Scored rotor surface

• | Grooved rotor surface

• | Excessive lateral runout

Refer to Brake Rotor Lateral Runout Check in Disc Brakes

Do any of the above conditions exist?

--

Go to Step 6

Go to Step 7

6 | Resurface or replace the brake rotor as necessary. Refer to Brake Rotor Refinishing , Front Brake Rotor Replacement or Rear Brake Rotor Replacement in Disc Brakes. Is the repair complete? | -- | Go to the Hydraulic Brake Diagnostic System Check | --
7 | Inspect the drum brakes for improper adjustment. Refer to Drum Brake Adjustment in Drum Brakes. Are the brakes improperly adjusted? | -- | Go to Step 8 | Go to Step 7
8 | Adjust the drum brakes properly. Refer to Drum Brake Adjustment in Drum Brakes. Is the repair complete? | -- | Go to the Hydraulic Brake Diagnostic System Check | --
9 | Inspect the brake assembly for missing or loose attachments. Refer to Brake Pad Inspection in Disc Brakes and Brake Shoe Inspection in Drum Brakes. Are there any missing or loose attachments? | -- | Go to Step 10 | Go to Step 13
10 | Repair or replace the components as necessary. Is the repair complete? | -- | Go to the Hydraulic Brake Diagnostic System Check | --
11 | Inspect the wheel cylinders and calipers for leakage. Are any of the components leaking? | -- | Go to Step 12 | Go to Step 13
12 | Replace the leaking components.

• | Repair or replace the FRONT brake calipers. Refer to Front Brake Caliper Overhaul or Front Brake Caliper Replacement in Disc Brakes.

• | Repair or replace the REAR brake calipers (export only). Refer to Rear Brake Caliper Overhaul or Rear Brake Caliper Replacement in Disc Brakes.

• | Repair or replace the wheel cylinders. Refer to Wheel Cylinder Overhaul or Wheel Cylinder Replacement in Drum Brakes.

Is the repair complete?

--

Go to the Hydraulic Brake Diagnostic System Check

--

13 | Inspect the hydraulic brake system for leaks. Refer to Brake Fluid Leak or Brake Hose Inspection . Is there any sign of leakage? | -- | Go to Step 14 | Go to Step 15
14 | Repair or replace the components as necessary. Is the repair complete? | -- | Go to the Hydraulic Brake Diagnostic System Check | --
15 | Inspect the master cylinder for leakage. Refer to Master Cylinder Diagnosis . Is the master cylinder leaking? | -- | Go to Step 16 | Go to Step 17
16 | Replace the master cylinder. Refer to Master Cylinder Replacement in Hydraulic Brake Systems. Is the repair complete? | -- | Go to the Hydraulic Brake Diagnostic System Check | --
17 | Inspect the brake system for air. Refer to Hydraulic Brake System Bleeding . Is there air in the system? | -- | Go to Step 18 | Go to Step 19
18 | Bleed the brake system. Refer to Hydraulic Brake System Bleeding . Is the repair complete? | -- | Go to the Hydraulic Brake Diagnostic System Check | --
19 | Inspect the brake fluid for contamination. Refer to Master Cylinder Reservoir Filling . Is the brake fluid contaminated? | -- | 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 Master Cylinder Replacement .
3. Repair or replace the master cylinder. Refer to Master Cylinder Overhaul .
4. Replace the front brake hoses. Refer to Front Brake Hose Replacement .
5. Replace the intermediate brake hoses. Refer to Brake Intermediate Hose Replacement .
6. Replace the rear brake hoses. Refer to Rear Brake Hose Replacement .
7. Repair or replace the FRONT brake calipers. Refer to Front Brake Caliper Overhaul or Front Brake Caliper Replacement in Disc Brakes.
8. Repair or replace the REAR brake calipers (export only). Refer to Rear Brake Caliper Overhaul or Rear Brake Caliper Replacement in Disc Brakes.
9. Repair or replace the wheel cylinders. Refer to Wheel Cylinder Overhaul or Wheel Cylinder Replacement in Drum Brakes.
10. Flush the hydraulic brake system. Refer to Hydraulic Brake System Flushing .

Is the repair complete?

--

Go to the Hydraulic Brake Diagnostic System Check

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21 | Verify the proper brake system operation. Does the original condition still exist? | -- | Go to Step 1 | System OK