Frelander 2. Manual — part 103
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1
Symptom
Possible Cause
Action
variation
Excessive brake disc runout
Wheel bearing wear or failure
Suspension bushing wear or failure
Steering bushing wear or failure
The brakes pull or drift
Tire pressures/wear
Brake calipers
Brake pads
Brake discs
Wheel alignment adjustment
Wheel bearing
Suspension bushings and ball joints
GO to Pinpoint Test
C.
The pedal feels spongy
Air in brake system
Leak in hydraulic system
Brake booster/master cylinder
failure
Brake pads
GO to Pinpoint Test
D.
The pedal goes down fast
Air in brake system
Leak in hydraulic system
Brake booster/master cylinder
Brake pads
GO to Pinpoint Test
E.
The pedal goes down
slowly
Air in brake system
Brake booster/master cylinder
GO to Pinpoint Test
F.
Excessive brake pedal
effort
Brake pads
Brake booster
GO to Pinpoint Test
G.
Brake lockup during light
brake pedal force
Brake pads
Brake calipers
GO to Pinpoint Test
H.
Brakes drag
Parking brake control
applied/malfunction
Seized parking brake cables
Seized caliper slide pins
Seized brake caliper
Brake booster
Pedal gear
GO to Pinpoint Test
I.
Excessive/Erratic brake
pedal travel
Hydraulic system
Brake pads
Brake discs
Hub and bearing assembly
GO to Pinpoint Test
J.
The red brake warning
indicator is always on
Fluid level
Brake fluid level sensor
Parking brake control
Electrical circuit
Fill the system to specification. Check for leaks.
Install a new brake master cylinder fluid reservoir
as required.
REFER to:
Brake Master Cylinder
(206-06 Hydraulic
Brake Actuation, Removal and Installation).
Check parking brake operation/electrical circuits.
REFER to:
Parking Brake
(206-05 Parking Brake and
Actuation, Diagnosis and Testing).
Slow or incomplete brake
pedal return
Brake pedal binding
Brake booster/master cylinder
GO to Pinpoint Test
K.
Pinpoint Tests
PINPOINT TEST A : BRAKES NOISY
TEST
CONDITIONS
DETAILS/RESULTS/ACTIONS
A1: INSPECT BRAKE PADS
Inspect the condition of the front and rear brake pads. Check for damage to any anti-squeal
shims.
Are the brake pads OK?
Yes
GO to A2
.
No
CLEAN or INSTALL new brake pads as required.
REFER to:
Brake Pads
(206-03 Front Disc Brake, Removal and Installation) /
Brake Pads
(206-04 Rear Disc Brake, Removal and Installation).
Test the system for normal operation.
A2: INSPECT BRAKE DISCS
Inspect the brake discs for excessive corrosion, wear or disc thickness variation.
Does excessive corrosion, wear or disc thickness variation exist?
Yes
INSTALL new brake discs and brake pads as required.
REFER to:
Brake Pads
(206-03 Front Disc Brake, Removal and Installation) /
Brake Disc
(206-03 Front Disc Brake, Removal and Installation) /
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1
1
1
1
1
1
1
Brake Pads
(206-04 Rear Disc Brake, Removal and Installation) /
Brake Disc
(206-04 Rear Disc Brake, Removal and Installation).
TEST the system for normal operation.
No
Vehicle is OK.
PINPOINT TEST B : VIBRATION WHEN BRAKES ARE APPLIED
TEST
CONDITIONS
DETAILS/RESULTS/ACTIONS
B1: ROAD TEST VEHICLE
Road test the vehicle between 40-80 km/h (25-50 mph) without applying brakes.
Is the vibration present?
Yes
TEST for noise vibration and harshness (wheel/tire balance, worn/damaged suspension
bushings/components, etc.). REPEAT road test if necessary.
No
GO to B2
.
B2: CHECK FOR BRAKE VIBRATION
Road test the vehicle between 40-80 km/h (25-50 mph) with light and medium application on the
brake pedal.
Is a vibration present?
Yes
CHECK the brake caliper mounting bolts and wheel hub nuts and TIGHTEN as necessary. CHECK the
balance of all road wheels and tires and REPAIR as necessary. CHECK the brake discs for excessive
wear, runout, thickness variation or cracks. INSTALL new brake discs and brake pads as required.
GO
to B3
.
No
Vehicle is OK.
B3: IS VIBRATION STILL PRESENT UNDER BRAKE APPLICATION?
Road test the vehicle between 40-80 km/h (25-50 mph) with light and medium application on the
brake pedal.
Is a vibration present?
Yes
CHECK for wear or failure of steering gear bushings. CHECK for wear or failure of steering gear ball
joints. CHECK for wear or failure of front wheel bearings, suspension bushings and ball joints. CHECK
for wear or failure of rear wheel bearings, suspension bushings and ball joints. REFER to relevant
section in workshop manual and INSTALL new components as required.
No
Vehicle is OK.
PINPOINT TEST C : THE BRAKES PULL OR DRIFT
TEST
CONDITIONS
DETAILS/RESULTS/ACTIONS
C1: ROAD TEST VEHICLE
Road test the vehicle and apply the brake pedal.
Does the vehicle pull or drift?
Yes
GO to C2
.
No
Vehicle is OK.
C2: INSPECT TIRE CONDITION/PRESSURE
Check for excessive tire wear or incorrect pressures.
Are the tires at the correct pressure and in good condition?
Yes
GO to C3
.
No
ADJUST the tire pressures or INSTALL new tires if excessively worn. TEST the system for normal
operation.
C3: CHECK CALIPERS
Check the disc brake caliper pistons and pins for binding, leaking or sticking.
Do the disc brake caliper pistons and pins bind, leak or stick?
Yes
RECTIFY sticking pins and INSTALL new brake calipers as required.
REFER to: Brake Caliper (206-03 Front Disc Brake, Removal and Installation) /
Brake Caliper
(206-04 Rear Disc Brake, Removal and Installation).
TEST the system for normal operation.
No
GO to C4
.
C4: INSPECT BRAKE DISCS
Check the brake discs for excessive damage, thickness variation or runout.
Does excessive damage or runout exist?
Yes
INSTALL new brake discs and brake pads as required. TEST the system for normal operation.
No
GO to C5
.
C5: INSPECT THE FRONT HUB AND WHEEL BEARING ASSEMBLY
Check the front hub and wheel bearing assembly.
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1
1
1
2
3
4
5
6
7
1
1
Are the wheel bearings OK?
Yes
GO to C6
.
No
INSTALL new wheel bearings as required.
REFER to:
Front W heel Bearing
(204-01 Front Suspension, Removal and Installation).
TEST the system for normal operation.
C6: CHECK SUSPENSION BUSHINGS AND BALL JOINTS
Check all suspension bushings and ball joints.
Are the suspension bushings and ball joints OK?
Yes
Check and adjust steering geometry
REFER to: Four-Wheel Alignment (204-00 Suspension System - General Information, General
Procedures).
No
INSTALL new suspension bushings and ball joints as required. REFER to the relevant section in the
workshop manual.
PINPOINT TEST D : THE PEDAL FEELS SPONGY
TEST
CONDITIONS
DETAILS/RESULTS/ACTIONS
D1: CHECK FOR SPONGY PEDAL (ENGINE OFF)
Check for a firm brake pedal.
Is the brake pedal effort and brake pedal travel normal?
Yes
Vehicle is OK.
No
GO to D2
.
D2: CHECK BRAKE PEDAL RESERVE (ENGINE OFF)
Pump the brake pedal 10 times and hold on the final application.
Does the brake pedal feel firm on final application?
Yes
GO to D3
.
No
BLEED the brake system.
REFER to:
Brake System Bleeding
(206-00 Brake System - General Information, General
Procedures) /
Brake System Pressure Bleeding
(206-00 Brake System - General Information, General Procedures).
D3: CHECK BRAKE PEDAL RESERVE (ENGINE ON)
Apply Parking Brake and ensure transmission is in park/neutral.
Start engine and allow to idle.
Apply the brake pedal lightly three or four times.
Wait 15 seconds for the vacuum to recover.
Push down on the brake pedal until it stops moving downward or an increased resistance to the
brake pedal travel occurs.
Hold the brake pedal in the applied position while increasing the engine speed to 2000 rpm.
Release the accelerator pedal.
Does the brake pedal move downward as the engine speed returns to idle?
Yes
GO to D4
.
No
CHECK the vacuum to brake booster.
D4: CHECK BRAKE FLUID LEVEL
Check the brake master cylinder reservoir fluid level.
Is the fluid level OK?
Yes
BLEED the brake system.
REFER to:
Brake System Bleeding
(206-00 Brake System - General Information, General
Procedures) /
Brake System Pressure Bleeding
(206-00 Brake System - General Information, General Procedures).
TEST the system for normal operation.
No
CHECK for leaking brake system and RECTIFY as necessary. ADD fluid and BLEED the brake
system.
REFER to:
Brake System Bleeding
(206-00 Brake System - General Information, General
Procedures) /
Brake System Pressure Bleeding
(206-00 Brake System - General Information, General Procedures).
TEST the system for normal operation. REPEAT road test if required.
PINPOINT TEST E : THE PEDAL GOES DOWN FAST
TEST
CONDITIONS
DETAILS/RESULTS/ACTIONS
E1: ROAD TEST VEHICLE
Road test the vehicle and apply the brake pedal.
Is the brake pedal effort and brake pedal travel normal?
Yes
Vehicle is OK.
No
GO to E2
.
E2: PRESSURIZE SYSTEM AND CHECK BRAKE PEDAL TRAVEL
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1
1
1
1
2
3
4
1
2
3
4
1
With the vehicle stationary pump the brake pedal rapidly (five times).
Does the brake pedal travel build up and then hold?
Yes
BLEED the brake system.
REFER to:
Brake System Bleeding
(206-00 Brake System - General Information, General
Procedures) /
Brake System Pressure Bleeding
(206-00 Brake System - General Information, General Procedures).
TEST the system for normal operation.
No
GO to E3
.
E3: CHECK FOR BRAKE SYSTEM LEAKS
Check for external brake system leaks. For additional information, refer to brake master cylinder
component test in this section.
Are leaks found?
Yes
REPAIR as necessary, ADD fluid and BLEED brake system.
REFER to:
Brake System Bleeding
(206-00 Brake System - General Information, General
Procedures) /
Brake System Pressure Bleeding
(206-00 Brake System - General Information, General Procedures).
TEST the system for normal operation.
No
System is OK.
PINPOINT TEST F : THE PEDAL GOES DOWN SLOWLY
TEST
CONDITIONS
DETAILS/RESULTS/ACTIONS
F1: CHECK FOR BRAKE SYSTEM LEAKS
Check for external brake system leaks. For additional information, refer to brake master cylinder
component test in this section.
Are there any external brake system leaks?
Yes
REPAIR as necessary. ADD fluid and BLEED the brake system.
REFER to:
Brake System Bleeding
(206-00 Brake System - General Information, General
Procedures) /
Brake System Pressure Bleeding
(206-00 Brake System - General Information, General Procedures).
TEST the system for normal operation.
No
Check for brake master cylinder internal leaks, refer to brake master cylinder component test in
this section, and repair as necessary.
PINPOINT TEST G : EXCESSIVE BRAKE PEDAL EFFORT
TEST
CONDITIONS
DETAILS/RESULTS/ACTIONS
G1: CHECK BRAKE PADS
Check the brake pads for wear, contamination, correct installation, damage and type.
Are any concerns found?
Yes
INSTALL brake pads correctly or INSTALL new brake pads as required.
REFER to:
Brake Pads
(206-03 Front Disc Brake, Removal and Installation) /
Brake Pads
(206-04 Rear Disc Brake, Removal and Installation).
TEST the system for normal operation. REPEAT road test.
No
GO to G2
.
G2: CHECK VACUUM
Disconnect the vacuum hose from the brake booster.
Connect a vacuum/pressure tester to the vacuum hose.
Run the engine at normal operating temperature.
Record the vacuum reading.
Is the reading 90 kPa (26.5 in-Hg) or greater
Yes
GO to G3
.
No
LOCATE and REPAIR the source of low vacuum. TEST the system for normal operation.
G3: INSPECT SYSTEM
Switch the engine off.
Reconnect the vacuum hose.
Inspect the brake booster, rubber grommet, and all vacuum plumbing for cracks, holes, damaged
connections, or missing clamps.
Pump the brake pedal several times to exhaust the vacuum. Push down on the brake pedal and
hold.
Does the brake pedal move down when the engine is started?
Yes
Vacuum system is OK.
No
GO to G4
.
G4: CHECK POWER BRAKE BOOSTER VALVE
Check the brake booster valve. For additional information, refer to Brake Booster component test in
this section.
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