411 / 745
BRAKES
8
4. GENERAL SYMPTOMS DIAGNOSIS
PROBLEM
CAUSE
REMEDY
SPONGY BRAKE
PEDAL
1. Air in hydraulic system.
2. Soft or weak hose.
3. Poor quality brake fluid.
4. Low brake fluid level.
5. Pedal return spring came out /
broken.
6. One of both primary seals damaged
in TMC.
1. Bleed the system and top up.
2. Check and Replace.
3. Flush the system and refill with
recommended grade of brake fluid.
4. Top up the brake fluid.
5. Check and replace.
6. Check and replace TMC.
BRAKE ROUGH OR
CHATTER ON
APPLICATION
1. Excessive lateral run out in disc or
parallelism.
2. Broken anti-rattle clip.
3. Incorrect parking brake adjustment.
4. Seized caliper pistons.
5. Damaged or loose wheel bearing.
6. Distorted steering knuckle or rear
wheel spindle.
7. Caliper bolt loosened.
1. Replace the disc.
2. Replace.
3. Check and adjust as per
specifications.
4. Overhaul Calipers.
5. Replace wheel bearing.
6. Replace knuckle or rear wheel
spindle.
7. Tighten the bolt to the specified
torque.
EXCESSIVE BRAKE
PEDAL EFFORT
(HARD
PEDAL)
1. Lining soiled with brake fluid, oil or
grease.
2. Malfunctioning of Servo.
3. Partial system failure (in tandem
master cylinder).
4. Piston in calipers stuck or sluggish.
5. Fading brake due to non-
recommended grade of brake pads.
6. Kinked dented or clogged bundy
pipes, hoses.
7. Binding pedal linkage.
8. Vacuum leakage through the system.
9. Booster NRV or NRV line faulty/ not
working.
10. Vacuum pump defective.
1. Replace.
2. Identify the trouble in Servo and
rectify.
3. Check both front and rear circuits
and rectify.
4. Remove caliper and rebuild.
5. Replace with approve grade of
brake pads.
6. Identify and Replace.
7. Lubricate and free up the system.
8. Rectify the leakage.
9. Replace the NRV.
10. Replace vacuum pump.