HYDRAULIC BRAKE AND PARK BRAKE
SYSTEMS
Brake System Troubleshooting
6
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
Excessive clearance between the disc and
brake pads
See Brake Pads and Caliper on page 6-7.
Leak in the hydraulic system
Check the master cylinder, brake hoses and
connections for leaks. Replace all damaged
parts and bleed brake system.
Air in the hydraulic system
See Bleeding the Hydraulic Brake System
Weak (bulging) brake hose
Replace the worn hose.
Low pedal – pedal may go to the floor
Improperly adjusted master cylinder push rod
See Brake Pedal Adjustment, Section 5,
Cracked or thin disc
Replace brake discs.
Poor quality brake fluid or water in fluid
Purge hydraulic fluid and fill with approved
DOT 5 (silicone) brake fluid.
Hydraulic System on page 6-20.
Weak (bulging) brake hoses that expand under
pressure
Check the master cylinder and brake hoses for
leaks or bulges. Replace all damaged parts.
Springy or spongy brake pedal – brake pedal
has soft, springy, or spongy feel when pressed
Air in the hydraulic system
See Bleeding the Hydraulic Brake System
Grease or brake fluid on the brake discs or
pads
Replace the hub or axle seal and replace the
brake pads.
Glazed brake pads
Replace the brake pads.
Damaged or distorted brake pads
Replace the brake pads.
Clogged brake hoses
Replace brake hoses as required.
Hose Replacement on page 6-14.
Hard pedal – excessive pedal pressure is
required to stop the vehicle
Frozen master cylinder piston or bent rod
Replace master cylinder.
Cylinder and Reservoir on page 6-17.
Over- aggressive braking
Incorrect or distorted brake pads
Replace the brake pads.
TABLE CONTINUED ON NEXT PAGE
2016 Carryall 1500/1700 and XRT 1550 Maintenance and Service Manual
Page 6-5
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