Frelander 2. Manual - part 103

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

The pedal feels spongy

Air in brake system
Leak in hydraulic system
Brake booster/master cylinder
failure
Brake pads

GO to Pinpoint Test

The pedal goes down fast

Air in brake system
Leak in hydraulic system
Brake booster/master cylinder
Brake pads

GO to Pinpoint Test

The pedal goes down
slowly

Air in brake system
Brake booster/master cylinder

GO to Pinpoint Test

Excessive brake pedal
effort

Brake pads
Brake booster

GO to Pinpoint Test

Brake lockup during light
brake pedal force

Brake pads
Brake calipers

GO to Pinpoint Test

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

Excessive/Erratic brake
pedal travel

Hydraulic system
Brake pads
Brake discs
Hub and bearing assembly

GO to Pinpoint Test

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

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

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) /

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.

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.

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.

to B3

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.

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

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

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.

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.

GO to C5

C5: INSPECT THE FRONT HUB AND WHEEL BEARING ASSEMBLY

Check the front hub and wheel bearing assembly.

1
2
3
4
5

6
7

Are the wheel bearings OK?
Yes

GO to C6

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).

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.

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

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

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.

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.

GO to E2

E2: PRESSURIZE SYSTEM AND CHECK BRAKE PEDAL TRAVEL

1
2
3
4

1
2
3

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.

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.

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.

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.

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

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.

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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