CONVENTIONAL BRAKE SYSTEM — PREPARATION (SST) / TROUBLESHOOTING GUIDE

P-6spec table

Special Service Tools (SST) (continued)

Part number	Name	Usage
49 U043 004	Gauge, oil pressure (Part of 49 U043 0A0)	For inspection of brake fluid pressure
49 U043 005	Joint (Part of 49 U043 0A0)	For inspection of brake fluid pressure
49 U043 006	Hose (Part of 49 U043 0A0)	For inspection of brake fluid pressure
49 B043 001	Adjust gauge	For adjustment of push rod clearance

49 U043 004

NameGauge, oil pressure (Part of 49 U043 0A0)

UsageFor inspection of brake fluid pressure

49 U043 005

NameJoint (Part of 49 U043 0A0)

UsageFor inspection of brake fluid pressure

49 U043 006

NameHose (Part of 49 U043 0A0)

UsageFor inspection of brake fluid pressure

49 B043 001

NameAdjust gauge

UsageFor adjustment of push rod clearance

TROUBLESHOOTING GUIDE

Troubleshooting guide

Problem	Possible cause	Remedy	Page
Poor braking	Leakage of brake fluid	Repair	P-8
Poor braking	Air in system	Bleed air	P-7
Poor braking	Worn pad or lining	Replace	P-32,37,42
Poor braking	Brake fluid, grease, oil, or water on pad or lining	Clean or replace	P-32,37,42
Poor braking	Hardening of pad or lining surface or poor contact	Grind or replace	P-32,37,42
Poor braking	Malfunction of disc brake piston	Replace	P-33,40
Poor braking	Malfunction of master cylinder or wheel cylinder	Repair or replace	P-14,19,35,40,42,44
Poor braking	Malfunction of power brake unit	Repair or replace	P-28,29
Poor braking	Malfunction of check valve (vacuum hose)	Replace	P-28
Poor braking	Damaged vacuum hose	Replace	—
Poor braking	Deterioration of flexible hose	Replace	—
Poor braking	Malfunction of dual proportioning valve	Replace	P-30
Brakes pull to one side	Worn pad or lining	Replace	P-32,37,42
Brakes pull to one side	Brake fluid, grease, oil, or water on pad or lining	Clean or replace	P-32,37,42
Brakes pull to one side	Hardening of pad or lining surface or poor contact	Grind or replace	P-32,37,42
Brakes pull to one side	Abnormal wear or distortion of disc, drum, pad, or lining	Repair or replace	P-32,37,42
Brakes pull to one side	Malfunction of automatic adjuster	Repair or replace	—
Brakes pull to one side	Looseness of backing plate / dust cover mounting bolts	Tighten	Section M
Brakes pull to one side	Malfunction of wheel cylinder	Repair or replace	P-35,40,42
Brakes pull to one side	Improperly adjusted wheel alignment	Adjust	Section R
Brakes pull to one side	Unequal tire air pressures	Adjust	Section Q
Brakes do not release	No brake pedal play	Adjust	P-13
Brakes do not release	Improperly adjusted push rod clearance	Adjust	P-15,20
Brakes do not release	Clogged master cylinder return port	Clean	—
Brakes do not release	Weak brake pad or shoe return spring	Replace	P-32,37,42
Brakes do not release	Wheel cylinder not returning properly	Clean or replace	P-42,44
Brakes do not release	Malfunction of piston seal of disc brake	Replace	P-35,40
Brakes do not release	Excessive runout of disc plate	Replace	P-34,39
Pedal goes too far (too much pedal stroke)	Improperly adjusted pedal play	Adjust	P-13
Pedal goes too far (too much pedal stroke)	Worn pad or lining	Replace	P-32,37,42
Pedal goes too far (too much pedal stroke)	Air in system	Bleed air	P-10
Abnormal noise or vibration during braking	Worn pad or lining	Replace	P-32,37,42
Abnormal noise or vibration during braking	Deteriorated pad or lining	Grind or replace	P-32,37,42
Abnormal noise or vibration during braking	Brakes do not release	Repair	—
Abnormal noise or vibration during braking	Foreign material or scratches on disc plate or drum contact surface	Clean	P-33,38,42
Abnormal noise or vibration during braking	Looseness of backing plate / dust cover or caliper mounting bolts	Tighten	Section M, P-33,38
Abnormal noise or vibration during braking	Damaged disc or drum contact surface	Replace	P-33,38,42
Abnormal noise or vibration during braking	Poor contact of pad or lining	Repair or replace	P-32,37,42
Abnormal noise or vibration during braking	Insufficient grease on sliding parts	Grease	—
Steering wheel pulls to one side	Dragging brake	Repair	—
Steering wheel pulls to one side	Malfunction of steering system	—	Section N
Steering wheel pulls to one side	Damaged or unbalanced wheels	—	Section Q
Steering wheel pulls to one side	Incorrect tire pressure	—	Section Q
Steering wheel pulls to one side	Malfunction of suspension	—	Section R

Poor braking

Possible causeLeakage of brake fluid

RemedyRepair

PageP-8

Poor braking

Possible causeAir in system

RemedyBleed air

PageP-7

Poor braking

Possible causeWorn pad or lining

RemedyReplace

PageP-32,37,42

Poor braking

Possible causeBrake fluid, grease, oil, or water on pad or lining

RemedyClean or replace

PageP-32,37,42

Poor braking

Possible causeHardening of pad or lining surface or poor contact

RemedyGrind or replace

PageP-32,37,42

Poor braking

Possible causeMalfunction of disc brake piston

RemedyReplace

PageP-33,40

Poor braking

Possible causeMalfunction of master cylinder or wheel cylinder

RemedyRepair or replace

PageP-14,19,35,40,42,44

Poor braking

Possible causeMalfunction of power brake unit

RemedyRepair or replace

PageP-28,29

Poor braking

Possible causeMalfunction of check valve (vacuum hose)

RemedyReplace

PageP-28

Poor braking

Possible causeDamaged vacuum hose

RemedyReplace

Page—

Poor braking

Possible causeDeterioration of flexible hose

RemedyReplace

Page—

Poor braking

Possible causeMalfunction of dual proportioning valve

RemedyReplace

PageP-30

Brakes pull to one side

Possible causeWorn pad or lining

RemedyReplace

PageP-32,37,42

Brakes pull to one side

Possible causeBrake fluid, grease, oil, or water on pad or lining

RemedyClean or replace

PageP-32,37,42

Brakes pull to one side

Possible causeHardening of pad or lining surface or poor contact

RemedyGrind or replace

PageP-32,37,42

Brakes pull to one side

Possible causeAbnormal wear or distortion of disc, drum, pad, or lining

RemedyRepair or replace

PageP-32,37,42

Brakes pull to one side

Possible causeMalfunction of automatic adjuster

RemedyRepair or replace

Page—

Brakes pull to one side

Possible causeLooseness of backing plate / dust cover mounting bolts

RemedyTighten

PageSection M

Brakes pull to one side

Possible causeMalfunction of wheel cylinder

RemedyRepair or replace

PageP-35,40,42

Brakes pull to one side

Possible causeImproperly adjusted wheel alignment

RemedyAdjust

PageSection R

Brakes pull to one side

Possible causeUnequal tire air pressures

RemedyAdjust

PageSection Q

Brakes do not release

Possible causeNo brake pedal play

RemedyAdjust

PageP-13

Brakes do not release

Possible causeImproperly adjusted push rod clearance

RemedyAdjust

PageP-15,20

Brakes do not release

Possible causeClogged master cylinder return port

RemedyClean

Page—

Brakes do not release

Possible causeWeak brake pad or shoe return spring

RemedyReplace

PageP-32,37,42

Brakes do not release

Possible causeWheel cylinder not returning properly

RemedyClean or replace

PageP-42,44

Brakes do not release

Possible causeMalfunction of piston seal of disc brake

RemedyReplace

PageP-35,40

Brakes do not release

Possible causeExcessive runout of disc plate

RemedyReplace

PageP-34,39

Pedal goes too far (too much pedal stroke)

Possible causeImproperly adjusted pedal play

RemedyAdjust

PageP-13

Pedal goes too far (too much pedal stroke)

Possible causeWorn pad or lining

RemedyReplace

PageP-32,37,42

Pedal goes too far (too much pedal stroke)

Possible causeAir in system

RemedyBleed air

PageP-10