1144 / 1906
BRAKES
7
PROBLEM
CAUSE
REMEDY
Excessive Pedal Travel
1. Incorrect pedal free play.
2. Partial brake system failure either in
dual circuit or in Master Cylinder.
3. Air in system (pedal soft / spongy).
4. Soft or bulging hose.
5. Excessive clearance between lining
and drum in rear brakes due to
malfunctioning of auto adjusters.
6. Lining pad knock back caused by
loose or worn wheel bearing or other
related parts.
7. Insufficient fluid in master cylinder
reservoir
1. Adjust as per specification.
2. Identify and repair by replacing
necessary parts.
3. Bleed
and
top
up
with
recommended brake fluid.
4. Replace.
5. Check auto adjuster mechanism.
6. Adjust or replace faulty parts as
necessary.
7. Fill reservoir with approved brake
fluid check for leak and air in brake
system. Check warning light, bleed
system if required.
Uneven Wear On Brake
Lining Material.
1. Check for correct type of brake lining
materials.
2. Wheel cylinders corroded.
1. Fit approved makes only.
2. Clean/rectify the cylinders.
Pistons Seized In
Wheel Cylinders.
1. Shoe assembly linkages dirty or
corroded.
2. Mounting of wheel cylinder out of line
or loose.
3. Corrosion of cylinder bores.
1. Check, rectify and free parts.
2. Check and rectify.
3. Remove corrosion/rectify.
Parking Brake
Ineffective.
1. Brake shoe greasy.
2. Excessive clearance between brake
lining and drum.
3. Excessive free play of cables.
1. Change brake shoe after rectifying
the cause of leakage if any.
2. Check and rectify auto adjuster
mechanism.
3. Adjust cables.
NOTE
If the above problems are not there then proceed further with the checking of brakes for grabbing
1.3 MAINTENANCE, INSPECTION AND TEST
DO’S :
Do inspect fluid level regularly and top up if
necessary
Do exercise scrupulous cleanliness when
dealing with hydraulic system.
Do use only fresh brake fluid or alcohol for
cleaning internal parts of the hydraulic system.
Do use only genuine kits for servicing the
cylinders.
Do use only genuine DOT-4 brake fluid.
Do fill the oil till max level whenever the
system is flushed completely then while
bleeding.
Do use fluid from sealed container.
DON’TS :