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 :
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