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 | Is the operator riding the brake pedal? | -- | Advise the customer of proper braking procedures. | Go to Step 3
3 | Inspect the brake pedal assembly for the following:

• | Bent or misaligned components

• | Binding or interference between the pedal and the booster input rod

• | Interference with other components

Do any of the above conditions exist?

--

Go to Step 4

Go to Step 5

4 | Repair or replace the cause of the misalignment, interference or binding. Is the repair complete? | -- | Go to Hydraulic Brake Diagnostic System Check | --
5 | Inspect the brake linings for the following:

• | Excessive wear

• | Uneven wear

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 6

Go to Step 7

6 | Replace the brake linings. Refer to Brake Pad Inspection in Disc Brakes and Brake Shoe Inspection in Drum Brakes. Is the repair complete? | -- | Go to Hydraulic Brake Diagnostic System Check | --
7 | 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 loose or missing attachments? | -- | Go to Step 8 | Go to Step 9
8 | Repair or replace the components as necessary. Is the repair complete? | -- | Go to Hydraulic Brake Diagnostic System Check | --
9 | Check for an improperly adjusted park brake. Is the park brake improperly adjusted? | -- | Go to Step 10 | Go to Step 11
10 | Adjust the park brake. Is the repair complete? | -- | Go to Hydraulic Brake Diagnostic System Check | --
11 | Inspect the front suspension for loose or missing attachments. Are there any loose or missing components? | -- | Go to Step 12 | Go to Step 13
12 | Repair or replace the components as necessary. Is the repair complete? | -- | Go to Hydraulic Brake Diagnostic System Check | --
13 | Inspect the disc brake caliper for the following:

• | Sticking caliper pistons

• | Corroded mounting bolts.

Do any of the above conditions exist?

--

Go to Step 14

Go to Step 15

14 | Replace the sticking or corroded components. Refer to Front Brake Caliper Overhaul or Rear Brake Caliper Overhaul in Disc Brakes. Is the repair complete? | -- | Go to Hydraulic Brake Diagnostic System Check | --
15 | Inspect the brake fluid for contamination. Is the brake fluid contaminated? | -- | Go to Step 16 | Go to Step 17
16 | 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

--

17 | Check the brake pipes and brake hoses for the following:

• | Low fluid or no fluid output

• | Particles suspended in the fluid

Refer to Hydraulic Brake System Flushing .

Do any of the above conditions exist?

--

Go to Step 18

Go to Step 19

18 |

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

Is the repair complete?

--

Go to Hydraulic Brake Diagnostic System Check

--

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