Pioneer 1200, Maintenance Service Manual

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MC012C-AS00 TRANSAXLE: HYDRAULIC AND PARK BRAKE SYSTEMS Brake System Troubleshooting
2003 Pioneer 1200/1200SE Gasoline Vehicle Maintenance and Service Manual Page 6-3
6
Brake Drum and Shoe Inspection
• Remove and inspect each brake drum. The drum should not be cracked or warped, or have excessive
scores or heat checks.
• Inspect the brake shoes. Shoes should not be distorted, cracked or have broken welds.
• Check the condition of the brake shoe linings. The brake shoe lining should not be glazed or soiled with
grease or brake fluid. There should be a minimum of 1/32-inch (0.8 mm) of usable lining remaining at
the thinnest point.
∆
WARNING
• Use only approved replacement brake drums designed for your vehicle. For MC012C-AS00
transaxles, use CC P/N 102264701.
Brake Cluster Assembly Inspection
• Check each wheel cylinder (7) by pulling back the edge of each dust boot (Figure 6-1, Page 6-2 or
Figure 6-19, Page 6-21). Brake fluid in the boot indicates a leaking wheel cylinder and should be
replaced. See Wheel Cylinder Replacement on page 6-19.
• Inspect the shoe hold-down parts and springs. Replace damaged items.
• If the brake adjusters (3) are frozen (requiring more than 65 in-lb (7.4 N·m) to turn freely), worn or
loose, replace the adjuster assemblies in pairs (Figure 6-1, Page 6-2). See Brake Shoe Adjuster
Replacement on page 6-21.
BRAKE SYSTEM TROUBLESHOOTING
The procedures used in making the checks provided in the following troubleshooting guide can be found in the
referenced sections of this maintenance and service manual.
TROUBLESHOOTING GUIDE
SYMPTOM POSSIBLE CAUSES CORRECTIVE ACTION
Low pedal – Pedal may go to the floor
Excessive clearance between the drums
and shoe linings
Front - Perform step 19 of Front Wheel
Brake Drum Installation on page 6-15.
Rear - Perform step 4 of Rear Wheel
Brake Drum Installation on page 6-16.
Automatic adjusters are not working
Make several forward and reverse brake
stops; if the pedal does not come up,
replace the automatic adjusters. See
Brake Shoe Adjuster Replacement on
page 6-21.
Bent or distorted brake shoes
Replace the brake shoes. See Brake
Shoe Removal on page 6-8.
Leak in the hydraulic system
Check the master cylinder, brake lines
and hoses for leaks. Replace all damaged
parts.
Air in the hydraulic system
See Bleeding the Hydraulic Brake
System on page 6-31.
Troubleshooting Guide continued on next page...