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34 90... Troubleshooting brake system

TROUBLESHOOTING CHART

Fault Cause Remedy
Brakes pull to one side
  1. a) Tyre inflation pressure not in keeping with regulations
  2. b) Unevenly worn tire treads
  3. c) Oil on pads/liners
  4. d) Wrong type of pads/liners
  5. f) Guide bolts dirty or damaged
  6. g) Axle geometry not correct
  7. h) Corrosion in floating calipers
  8. i) No shock absorber action
  9. k) Pad of one caliper worn
  1. a) Correct tire inflation pressure
  2. b) Change or replace tires
  3. c) Replace brake pads, Check for causes
  4. d) Replace brake pads, Check for causes
  5. f) Replace guide bolts
  6. g) Check wheel alignment
  7. h) Remove and install, repair or replace floating calipers
  8. i) Check shock absorbers, replace if necessary
  9. k) Replace brake pads, check floating caliper
Brakes excessively hot while driving
  1. a) Compensating port in brake master cylinder blocked
  2. c) Swollen rubber parts due to use of wrong brake fluid
  3. d) Bleeder hole on expansion tank blocked
  4. e) Corroded floating calipers
  5. f) Handbrake lever not released fully
  1. a) Replace brake master cylinder
  2. d) Clean expansion tank
  3. e) Remove and install, repair or replace floating calipers
  4. f) Check handbrake and handbrake Bowden cables, repair if necessary
Fault Cause Remedy
Poor braking effect in spite of great force on pedal
Travel at brake pedal normal		 Brake pads oil-splattered or burnt; wrong type of brake pads Replace brake pads
Poor braking effect in spite of great force on pedal
Travel at brake pedal too short		 Brake booster malfunctions - engine vacuum Check brake booster
Poor braking effect in spite of great force on pedal
Travel at brake pedal too long		 One brake circuit failed due to leaks or damage Leakage test of brake system
Brake pedal can be pressed down softly and springy
  1. a) Air in brake system
  2. b) Not enough brake fluid in expansion tank
  3. c) Overheated brake fluid - vapor lock due to excessive water content in brake fluid or excessive brake loads
  1. a) Bleed brakes
  2. b) Top up or change brake fluid Bleed brakes
  3. c) Change brake fluid, Bleed brakes
Brake is bled and readjusted, but brake pedal can be pressed down too far
  1. a) Primary cup seal in brake master cylinder damaged
  2. b) Leaking separating cup seals on floating piston of brake master cylinder
  3. c) Leak in brake system
  1. a) Replace master brake cylinder.
  2. b) Leakage test of brake system
Fault Cause Remedy
Uneven pad wear a) Wrong type of pads/liners a) Replace brake pads
  b) Dirty floating caliper recesses, damaged caps b) Remove and install, repair or replace floating calipers
  c) Corrosion in floating calipers c) Remove and install, repair or replace floating calipers
  d) Swollen rubber ring for piston control d) Remove and install, repair or replace floating calipers
Brake pads worn at angle a) Wheel-bearing play excessive a) Replace wheel bearings
  b) Brake disc not aligned with floating caliper b) Check floating caliper installation
  c) Corrosion in floating calipers c) Remove and install, repair or replace floating calipers
  d) Angular brake-disc wear d) Replace brake discs
  e) Minimum pad thickness undershot e) Replace brake pads
  f) Spring force insufficient f) Replace spring
  g) Guide bolts damaged g) Replace guide bolts
Seized brake pads, pad does not move off brake disc a) Dirty floating caliper recesses, damaged caps a) Remove and install, repair or replace floating calipers
  b) Corrosion in floating calipers b) Remove and install, repair or replace floating calipers
  c) Compensating port in brake master cylinder blocked c) Replace brake master cylinder
Fault Cause Remedy
Brakes squeal or rattle a) Wrong type of pads/liners a) Replace brake pads
  b) Dirty floating caliper recesses b) Remove and install/clean floating calipers
  c) Spring force insufficient c) Replace spring
  d) Brake disc not aligned with floating caliper d) Check floating caliper installation
  e) Brake-disc runout e) Replace brake discs
  f) Excessive thickness deviation within braking surface f) Measure brake disc thickness Replace discs
  g) Liner wear excessive or one-sided g) Replace brake shoes
  h) Rust edges on brake discs h) Replace brake discs
  i) Pad loose i) Replace brake pads
  j) Wheel-bearing play excessive j) Replace wheel bearings
Brake-pedal dead travel excessive a) Wheel-bearing play excessive a) Replace wheel bearings
  b) Brake disc not aligned with floating caliper b) Check floating caliper installation
  c) Brake-disc runout c) Replace brake discs
  d) Excessive thickness deviation within braking surface d) Measure brake disc thickness Replace discs
  e) Brake system leaking e) Leakage test of brake system
  f) Air in brake system f) Bleed brakes
  g) Wrong type of pads/liners g) Replace brake pads
Fault Cause Remedy
Jammed piston in brake caliper a) Dirty floating caliper recesses, damaged caps a) Remove and install, repair or replace floating caliper
  b) Brake disc not aligned with floating caliper b) Check floating caliper installation
  c) Pistons corroded in floating calipers c) Remove and install, repair or replace floating caliper
Pulsating effect on brake pedal a) Wheel-bearing play excessive a) Replace wheel bearings
  b) Brake disc not aligned with floating caliper b) Check floating caliper installation
  c) Brake-disc runout c) Replace brake discs
  d) Excessive thickness deviation within braking surface d) Measure brake disc thickness Replace discs
Handbrake effect insufficient a) Brake pad fouled by oil a) Replace brake pads, determine cause
  b) Excessive free play b) adjust handbrake
  c) Corroded transmitting elements c) Remove and install handbrake, check brake caliper, Bowden cables, replace if necessary
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