General Diagnostic Table: Inspection

GENERAL DIAGNOSTIC CHART

Trouble and possible cause		Corrective action
1. Insufficient braking	(1) Fluid leakage from the hydraulic mechanism	Correct or replace, (cup, piston seal, piston boot, master cylinder piston kit, pipe or hose)
	(2) Entry of air into the hydraulic mechanism	Bleed air.
	(3) Excessively wide shoe clearance	Adjust the clearance.
	(4) Wear, deteriorated surface material, water or fluid on lining	Replace, grind or clean.
	(5) Improper operation of master cylinder, disc caliper, brake booster or check valve	Correct or replace.
2. Unstable or uneven braking	(1) Fluid on the lining, drum or rotor	Correct the cause of fluid leakage, and clean or replace.
	(2) Drum or rotor problem	Repair or replace the drum or rotor.
	(3) Worn brake drum, or damage to the drum caused by entry of sand	Repair by grinding, or replace.
	(4) Improper lining contact, deteriorated surface, deteriorated or wear lining material	Repair by grinding, or replace.
	(5) Deformed back plate	Correct or replace.
	(6) Over inflation of tires	Adjust air pressure.
	(7) Defective wheel alignment	Adjust alignment.
	(8) Loose back plate or the support installation bolt	Tighten to the specified torque.
	(9) Loose wheel bearing	Replace.
	(10) Defective hydraulic system	Replace the cylinder, brake pipe or hose.
	(11) Unstable effect of parking brake	Check, adjust or replace the rear brake and cable system.
3. Excessive pedal stroke	(1) Entry of air into the hydraulic mechanism	Bleed air.
	(2) Excessive play in the master cylinder push rod	Adjust.
	(3) Fluid leakage from the hydraulic mechanism	Correct or replace, (cup, piston seal, piston boot, master cylinder piston kit, pipe or hose)
	(4) Improperly adjusted shoe clearance	Adjust.
	(5) Improper lining contact or worn lining	Correct or replace.
4. Brake dragging or improper brake return	(1) Insufficient pedal play	Adjust play.
	(2) Improper master cylinder return	Clean or replace the cylinder.
	(3) Clogged hydraulic mechanism	Replace.
	(4) Improper return or adjustment of parking brake	Repair or adjust.
	(5) Weakened spring tension or breakage of shoe return spring	Replace the spring.
	(6) Excessively narrow shoe clearance	Adjust the clearance.
	(7) Improper disc caliper operation	Correct or replace.
	(8) Faulty wheel bearing	Replace.
5. Brake noise (1) (creaking sound)	(1) Hardened or deteriorated lining	Replace the shoe assembly or pad.
	(2) Worn lining	Replace the shoe assembly or pad.
	(3) Loose back plate or the support installation bolt	Tighten to the specified torque.
	(4) Loose wheel bearing	Tighten to the specified torque.
	(5) Dirty drum or rotor	Clean the drum or rotor, or clean/replace the brake assembly.
6. Brake noise (2) (hissing sound)	(1) Worn lining	Replace the shoe assembly or pad.
	(2) Improperly installed brake shoe or pad	Repair or replace the shoe assembly or pad.
	(3) Loose or bent drum or rotor	Retighten or replace.
7. Brake noise (3) (click sound)	In the case of the disc brake:
	(1) Excessively worn pad or the support	Replace the pad or the support.
	In the case of the drum brake:
	(1) Excessively worn shoe ridge	Replace the back plate.
	(2) Lack of oil on the shoe ridge surface and anchor	Supply grease.