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 | Check the tires for incorrect pressure. Is the tire pressure incorrect? | -- | Go to Step 3 | Go to Step 4
3 | Adjust the tires to the correct pressure. Refer to Tire Inflation Pressure Specifications in Maintenance and Lubrication. Is the repair complete? | -- | Go to Hydraulic Brake Diagnostic System Check | --
4 | Inspect the front suspension for loose components. Are there loose components? | -- | Go to Step 5 | Go to Step 6
5 | Repair or replace the components as necessary. 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

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 7

Go to Step 8

7 | 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 Hydraulic Brake Diagnostic System Check

--

8 | Inspect the brake rotor for the following:

• | Hot spots

• | Scored rotor surface

• | Grooved rotor surface

Do any of the above conditions exist?

--

Go to Step 9

Go to Step 10

9 | 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 Hydraulic Brake Diagnostic System Check | --
10 | Inspect the brake assembly for loose, broken or missing components. Are there any loose, broken or missing brake assembly components? | -- | Go to Step 11 | Go to Step 12
11 | Repair or replace the components as necessary.

• | 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 Hydraulic Brake Diagnostic System Check

--

12 | 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 13

Go to Step 14

13 | Repair or replace the brake calipers. Refer to the applicable repair procedures.

• | For the FRONT brake calipers, refer to Front Brake Caliper Overhaul or Front Brake Caliper Replacement in Disc Brakes.

• | For the REAR brake calipers, refer to Rear Brake Caliper Overhaul or Rear Brake Caliper Bracket Replacement in Disc Brakes.

Is the repair complete?

--

Go to Hydraulic Brake Diagnostic System Check

--

14 | Inspect the park brake for improper adjustment. Is the park brake adjusted improperly? | -- | Go to Step 15 | Go to Step 16
15 | 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 | --
16 | Inspect the front suspension for incorrect alignment. Refer to Wheel Alignment Measurement in Wheel Alignment. Is the wheel alignment incorrect? | -- | Go to Step 17 | Go to Step 18
17 | Correct the front wheel alignment. Refer to Front Camber Adjustment and Front Toe Adjustment in Wheel Alignment. Is the repair complete? | -- | Go to Hydraulic Brake Diagnostic System Check | --
18 | Inspect for contaminated or improper brake fluid. Is the brake fluid contaminated or improper? | -- | Go to Step 19 | Go to Step 20
19 | 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 Hydraulic Brake Diagnostic System Check

--

20 |

1. Inspect for a restricted brake fluid passage.
2. 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 21

Go to Step 22

21 |

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 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

--

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