Hummer H1 (2002+). Manual - part 112

 

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Hummer H1 (2002+). Manual - part 112

 

 

 

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 Brake System  7-7

  

®

 

05745159

 

HYDRO-BOOST SYSTEM DIAGNOSIS

 

Noise Diagnosis

 

The following noises are associated with the hydro-boost and
may or may not be cause for concern. Some noises are normal
and for the most part temporary in nature. Other noises may be
a sign of excessive wear or the presence of air in either the
booster or the steering system. 

1.

A moan or low frequency hum usually accompanied by a 
vibration in the pedal or steering column may be observed 
during parking maneuvers or other low-speed maneuvers. 
This may be caused by a low fluid level in the power steer-
ing pump or by air in the fluid. Holding the pump at relief 
pressure (steering wheel held all the way in one direction) 
for more than five seconds will cause air to enter the sys-
tem. Check the fluid level and fill if needed. The system 
must then sit for one hour to remove the air. 

2.

A high-speed fluid noise may be heard when the brake
pedal is fully depressed. This condition is normal.

3.

Whenever the accumulator pressure is used, a slight hiss
may be noticed. It is the sound of the hydraulic fluid
escaping through the accumulator valve, and is completely
normal. 

4.

After the accumulator has been emptied and the engine is
started again, another hissing sound may be heard during
the first brake application or the first steering maneuver.
This is caused by the fluid rushing through the
accumulator charging orifice. It is normal and will only be
heard once after the accumulator is emptied. If this sound
continues however, even though no apparent accumulator
pressure assist was made, it could be an indication that the
accumulator is not holding pressure and should be
checked using the procedure 

 

Accumulator Leakdown Test

 

in this section. 

 

PROBLEM

POSSIBLE CAUSE

CORRECTION

 

Slow Brake Pedal 
Return
or
Brakes Apply When 
Turning Steering 
Wheel

1.

Damaged/broken return spring.

2.

Excessive seal friction in booster. 

3.

Faulty spool action. 

4.

Restriction in return line from booster to 
pump reservoir. 

5.

Damaged input rod end.

1.

Replace spring.

2.

Replace the hydro-boost. 

3.

Flush the steering system while pumping the 
brake pedal. 

4.

Replace the line. 

5.

Replace the hydro-booster. 

Grabs Suddenly
or
Booster Chatters - 
Pedal Vibrates

1.

Faulty spool action caused by contami-
nation.

2.

Power steering pump belt slips. 

3.

Low fluid level in power steering pump. 

1.

Flush steering system while pumping brake pedal.

2.

Replace tensioner and/or belt.

3.

Fill reservoir and check for external leaks.

Accumulator 
Leak-Down 
Reserve System 
Does Not Hold 
Charge

1.

Contamination in steering hydro-boost 
system.

2.

Internal leakage in accumulator system

1.

Flush steering system while pumping brake pedal.

2.

Replace hydro-boost.

Excessive Brake 
Pedal Efforts

1.

Loose, glazed, or broken pump belt.

2.

No fluid in pump reservoir.

3.

Leaks in system hoses.

4.

Leaks at tube fittings and connections.

5.

Leakage at pneumatic accumulator seal.

6.

Leakage at piston seal.

7.

Leakage at input seal.

8.

Leakage at cover-to-housing seal.

9.

Leakage at spool plug seal.

10. Leakage at ball plug

1.

Replace tensioner and/or replace belt.

2.

Fill reservoir and check for external leaks.

3.

Replace faulty parts.

4.

Tighten fittings or replace tube seats or O-rings.

5.

Replace O-ring.

6.

Overhaul with new seal kit.

7.

Overhaul with new seal kit.

8.

Overhaul with new seal kit.

9.

Overhaul with spool plug seal kit.

10. Replace hydro-boost.

 

NOTE: 

 

The power steering fluid and brake fluid cannot be mixed. If the brake seals contact steering fluid or the steering seals

contact brake fluid, seal damage will result.

 

7-8

Brake System

 

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®

 

Booster Functional Test

 

With the engine off, apply the brake pedal several times until
the accumulator is completely depleted. Depress the brake
pedal using 40 lb-ft (54 N•m) of force and start the engine. The
pedal will fall and then push back against your foot. 

 

Accumulator Leakdown Test

 

1.

Start the engine and charge the accumulator by applying 
the brake pedal or by turning the steering wheel from stop 
to stop. Turn off the engine and let the vehicle sit for one 
hour. After one hour there should be at least two power-
assisted applications with the engine off.

2.

If the reserve system will not retain a charge for one hour,
but functions normally immediately following charging,
the accumulator valves are at fault. Replace the hydro-
booster.

3.

If the accumulator can be heard charging and discharging
but does not hold a charge, replace the hydro-booster. 

4.

Deplete the accumulator by pressing the brake pedal
several times. If the accumulator can has lost its charge, it
is possible to rotate or wobble the accumulator can with
respect to the housing. Replace the hydro-booster. 

 

Handling

 

 - The booster should not be carried by the accumula-

tor nor should the booster ever be dropped on the accumulator.
The snap ring which holds the accumulator into the housing
should be checked for proper positioning before the booster is
used. The accumulator contains high pressure gas and with any
high pressure gas a certain degree of danger is present if mis-
handled.

 

Disposal

 

 - The accumulator should not be exposed to exces-

sive heat, fire or incineration. Before discarding accumulator
following replacement, drill a 1/16 inch diameter hole in the
end of accumulator can to relieve the pressure. BE SAFE! Pro-
tect your eyes. Wear approved safety glasses.

 

SERVICE BRAKE SYSTEM BLEEDING 

 

NOTE: 

 

If only the front or rear half of the system has been ser-

viced, it is usually necessary to bleed only that half of the sys-
tem. However, if a firm brake pedal cannot be obtained after
bleeding, it will be necessary to bleed the entire system. The
brake hydraulic system can be bled manually or by using a
pressure tank and adapters. Each method is outlined in the fol-
lowing procedures.

 

WARNING:  Disconnect the batteries before bleeding
the brake system. If the ABS modulator receives power
during the bleed procedure, air may become trapped in
areas in the modulator that cannot be bled by conven-
tional techniques. The modulator would need to be re-
placed to obtain a firm brake pedal.

WARNING:  If the reservoir has run very low or dry,
bleed the master cylinder before bleeding the remainder
of the brake system to keep from introducing additional
air into the system.

WARNING:  Always wear eye protection when bleeding
brakes. Failure to do this may cause injury if brake fluid
comes in contact with eyes.

 

Pressure Bleeding 

 

CAUTION: 

 

When using a pressure bleeding tank, (J–29532)

follow the manufacturer's instructions for its use. Use only
DOT 3 brake fluids when bleeding. Do not exceed the recom-
mended working pressure when pressurizing the tank. A tank
pressure of 15-20 psi (103-138 kPa) is sufficient to bleed the
brake hydraulic system. Release all air pressure from the tank
after using it.

 

NOTE: 

 

This procedure covers bleeding at one wheel. Repeat

bleeding task for remaining wheels.

1.

Disconnect batteries.

2.

Remove cap from master cylinder. Fill master cylinder if
necessary. 

3.

Install pressure tank bleeder adapter to master cylinder
(Figure 7-4).

4.

Connect line from pressure tank to adapter.

 

NOTE: 

 

Bleed calipers in the following order: right rear, left

rear, right front, left front.

5.

Remove protective cap from bleeder screw on caliper
assembly  (Figure 7-5).

6.

Connect short piece of hose to bleeder screw, and place
other end of hose in container 3/4 full of brake fluid.

7.

Open valve on line from pressure tank to master cylinder
allowing pressurized brake fluid to enter system 
 (Figure 7-4).

8.

Open bleeder screw 3/4 turn and observe brake fluid in
container. Close bleeder screw when brake fluid flows free
of air bubbles  (Figure 7-5).

9.

Disconnect hose from bleeder screw and install protective
cap on bleeder screw.

10. Close valve on line from pressure tank to master cylinder

(Figure 7-4).

11. Disconnect line from adapter.

12. Remove adapter from master cylinder and fill master

cylinder if necessary.

13. Install master cylinder cap. 

14. Connect batteries.

 

3-1-01

 

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 Brake System  7-9

 

 

®

 

05745159

 

Figure 7-4:   Pressure Bleeding Brake System

 

Manual Bleeding 

 

NOTE: 

 

This procedure covers bleeding at one wheel. Repeat

bleeding task for remaining wheels. Assistance is required to
depress the brake pedal when manually bleeding brakes while
mechanic opens and closes bleeder screw.

 

NOTE: 

 

Bleed calipers in the following order: right rear, left

rear, right front, left front.

1.

Disconnect batteries.

2.

Remove protective cap from bleeder screw on caliper
assembly  (Figure 7-5).

3.

Connect short piece of hose to bleeder screw, and place
other end of hose in container 3/4 full of brake fluid.

 

CAUTION: 

 

Check the master cylinder fluid level frequently

during the bleeding operation and refill the reservoirs as nec-
essary. Do not allow the master cylinder to run out of fluid at
any time, or additional air will be drawn into the system.

 

4.

Have an assistant depress the brake pedal. Open bleeder
screw 3/4 turn.

 

Figure 7-5:   Manually Bleeding Brake System

 

5.

When pedal reaches floor, tighten bleeder screw and have
assistant slowly release brake pedal.

6.

Repeat steps 3 and 4 until fluid flows clear and free of air
bubbles.

7.

Disconnect hose from bleeder screw and install protective
cap on bleeder screw.

8.

Connect batteries.

9.

Operate vehicle and check brakes for proper operation.

 

SERVICE BRAKE PAD REPLACEMENT

 

NOTE: 

 

The following procedure applies to the front brake

system only.

 

Removal 

 

1.

Using crowfoot, remove two capscrews and washers 
securing yoke and caliper to adapter.

 

NOTE: 

 

Note positioning of brake pad surfaces for installation.

2.

Remove yoke, caliper, and two brake pads.

 

Cleaning and Inspection 

 

NOTE: 

 

Clean all components, examine for wear or damage,

and replace if necessary.

PRESSURE TANK BLEEDER ADAPTER

MASTER CYLINDER

VALVE

PRESSURE TANK

BLEEDER SCREW

PROTECTIVE

CAP

HOSE

CALIPER 

ASSEMBLY

 

7-10

Brake System

 

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®

 

1.

Inspect dust boot for tears or deterioration (Figure 7-6).

2.

Inspect rotor for heat cracks, spotting, discoloration,
pitting, or scoring. Resurface rotors if discolored, pitted,
or scored. It is not recommended that rotors be turned
when spotted or heat cracks. 

3.

Inspect brake pads for glazing, oil saturation, or wear. If
glazed, oil saturated, or if brake lining thickness is less
than 1/8 in. (3.2 mm), replace brake pads. Brake pads
should be replaced as an axle set (front or rear).

 

Installation 

 

1.

Check brake pad backing plate notches for burrs or excess 
coating and ensure that the pad will fit the adapter slide 
with enough clearance to afford stick-free movement.

2.

Lubricate caliper guide pins, sleeves and adapter slides

with Permatex

 

® 

 

Ultra Disc Brake Caliper Lube prior to

installation.

 

WARNING:  Ensure brake pads are installed with lin-
ings facing rotor. Failure to do this will cause poor per-
formance, damage to equipment, and may result in
injury.

 

3.

Position brake pads on adapter.

 

NOTE: 

 

When installing yoke and caliper, use a suitable tool to

compress the piston.

4.

Apply a non-hardening thread-locking compound to
tapped holes of adapter. Using crowsfoot, secure yoke and
caliper to adapter with two washers and capscrews.
Tighten capscrews to 30-40 lb-ft (41-54 N•m).

 

LINING AND ROTOR BURNISHING

 

After you replace brake pads and/or refinish rotors, it is recom-
mended that the new braking surface be broken in, or “bur-
nished.” To do this, make 20 stops, one every one to two miles
at 30 mph, using medium pedal effort. The amount of time it
takes to stop should be approximately five seconds. During this
procedure, use care to avoid overheating the brakes.

 

Figure 7-6:   Caliper Assembly

 

FRONT SERVICE BRAKE CALIPER REPLACE-
MENT

 

NOTE: 

 

The following procedure applies to the front brake

system only. If removing left front caliper, halfshaft must be
removed.

 

Removal 

 

1.

Disconnect brake line from coupling (Figure 7-7).

2.

Using crowfoot, remove two capscrews and washers
securing yoke and caliper to adapter.

 

NOTE: 

 

Note positioning of brake pad surfaces for installation.

3.

Remove yoke, caliper, and two brake pads from adapter.

4.

Slide yoke and caliper guide pins out from caliper.
Remove coupling and washer from caliper.

 

Cleaning and Inspection 

 

NOTE: 

 

Clean all components, examine for wear or damage,

and replace if necessary.

1.

Clean mating surfaces of caliper and adapter  (Figure 7-7).

2.

Inspect caliper and caliper piston for pitting, or damage
(Figure 7-6).

3.

Inspect caliper guide pins and sleeves for wear.

4.

Inspect dust boot and bushings for tears or deterioration.

5.

Inspect yoke and caliper guide pins for corrosion. Perform
step 6 if corroded. If not, perform step 8 (Figure 7-7).

6.

Remove caliper guide pins from yoke. Discard caliper
guide pins.

7.

Inspect rotor for heat checks, discoloration, pitting, or
scoring. Check rotor thickness variation.

 

NOTE: 

 

Replace brake pads in sets only. Replace brake pads if

brake lining thickness is less than 1/8 in. (3.2 mm) and opera-
tion in wet and muddy conditions is expected.

8.

Inspect brake pads for glazing, oil saturation, or wear. If
glazed, oil saturated, or if brake lining thickness is less
than 1/8 in. (3.2 mm), replace both pads and pads from
opposite caliper. 

CALIPER

PISTON

DUST BOOT

 

4-1-00

 

 

 

 

 

 

 

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