Fastener Tightening Specifications
| Application | Specification |
| Metric | English |
| Antilock Brake System (ABS) Module Splash Shield Bolt | 20 N.m | 15 lb ft |
| Brake Booster Nut (Hydraulic Brake Booster) | 33 N.m | 24 lb ft |
| Brake Booster Nut (Vacuum Brake Booster) | 33 N.m | 24 lb ft |
| Brake Booster Pushrod Retainer Bolt | 10 N.m | 89 lb in |
| Brake Hose Bracket to Axle Housing Bolt (JD9) | 25 N.m | 18 lb ft |
| Brake Hose Bracket to Axle Housing Bolt (JH6) | 12 N.m | 106 lb in |
| Brake Hose Bracket to Control Arm Bolt | 9 N.m | 80 lb in |
| Brake Hose Bracket to Frame Bolt (Front) | 9 N.m | 80 lb in |
| Brake Hose Bracket to Frame Bolt (Rear) | 25 N.m | 18 lb ft |
| Brake Hose Bracket to Rear Axle Bolt (JD9) | 9 N.m | 80 lb in |
| Brake Hose Bracket to Steering Knuckle Bolt | 9 N.m | 80 lb in |
| Brake Hose Fitting Bolt (Front and Rear) | 40 N.m | 30 lb ft |
| Brake Master Cylinder Primary Piston Position Sensor Screw | 10 N.m | 89 lb in |
| Brake Modulator Manual Pressure Relief Valve | 40 N.m | 30 lb ft |
| Brake Pedal Bracket Nut | 25 N.m | 18 lb ft |
| Brake Pedal Pivot Nut | 35 N.m | 26 lb ft |
| Brake Pipe Fitting | 25 N.m | 18 lb ft |
| Brake Pipe Fitting - Master Cylinder (JD9, JH6) | 32 N.m | 24 lb ft |
| Brake Pipe Fitting - Master Cylinder (Two-mode Hybrid) | 30 N.m | 22 lb ft |
| High Pressure Accumulator (HPA) | 30 N.m | 22 lb ft |
| Master Cylinder Nut | 33 N.m | 24 lb ft |
| Master Cylinder Reservoir Pin (Two-mode Hybrid) | 8 N.m | 71 lb in |
Brake Component Specifications
| Application | Specification |
| Metric | English |
| Brake Pressure Modulator Bleeder Valves | 9 N.m | 80 lb in |
| Brake Caliper Bleeder Valve (Front) | 13 N.m | 115 lb in |
| Brake Caliper Bleeder Valve (Rear) | 11 N.m | 97 lb in |
Brake System Specifications
| Application | Specification |
| Metric | English |
| Brake Pedal Maximum Travel* |
| Hydraulic Power Assist | 90 mm | 3.54 in |
| *Specification with 445 N (100 lb) of force applied to the brake pedal, the ignition OFF, and the brake booster power reserve depleted. |
Scheme 1
Scheme 1: Hydraulic Brake Schematics
DIAGNOSTIC CODE INDEX
| DTC | Description |
| DTC C0267 | C0267 00: Low Brake Fluid Indicated |
| DTC C0299 | C0299 00: Brake Booster Pressure Sensor Performance C0299 5A: Brake Booster Pressure Sensor Performance Plausibility Failure |
| DTC C1100 | C1100 00: Base Brake System Pressure Circuit |
Diagnostic Instructions
- Perform the «Diagnostic System Check - Vehicle»(/cadillac/escalade/gmt900-2006-2014/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures) prior to using this diagnostic procedure.
- Review «Strategy Based Diagnosis»(/cadillac/escalade/gmt900-2006-2014/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__strategy-based-diagnosis) for an overview of the diagnostic approach.
- «Diagnostic Procedure Instructions»(/cadillac/escalade/gmt900-2006-2014/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__diagnostic-procedure-instructions) provides an overview of each diagnostic category.
Diagnostic Fault Information
| Circuit | Short to Ground | Open/High Resistance | Short to Voltage | Signal Performance |
| Brake Fluid Level Signal | C0267 00 | 1 | 1 | |
| Park Brake Signal | 1 | 1 | 1 | |
| Ground | | 1 | | |
| 1. Brake Warning Indicator Malfunction |
Circuit/System Description
The brake fluid level switch monitors the level of brake fluid in the master cylinder. When the instrument panel cluster (IPC) sees the brake fluid level switch input closed, it turns ON the Red Brake Warning indicator and sends a serial data message to the electronic brake control module (EBCM) that the brake fluid level is low.
Conditions for Running the DTC
Conditions for Setting the DTC
- Low brake fluid is detected.
- A short to ground exists on the signal circuit.
Action Taken When the DTC Sets
- The EBCM disables the antilock brake system (ABS)/traction control system (TCS) dynamic rear proportion (DRP) and vehicle stability enhancement system (VSES).
- A DIC message and/or a warning indicator may be displayed.
Conditions for Clearing the DTC
- The condition for the DTC is no longer present.
- The EBCM clears the history DTC when a current DTC is not detected in 100 consecutive drive cycles.
Reference Information
Connector End View Reference
Description and Operation
Electrical Information Reference
- «Circuit Testing»(/cadillac/escalade/gmt900-2006-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__circuit-testing)
- «Connector Repairs»(/cadillac/escalade/gmt900-2006-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__connector-repairs)
- «Testing for Intermittent Conditions and Poor Connections»(/cadillac/escalade/gmt900-2006-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__testing-for-intermittent-conditions-and-poor)
- «Wiring Repairs»(/cadillac/escalade/gmt900-2006-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__wiring-repairs)
Circuit/System Verification
- Inspect for proper brake fluid level, the fluid level should be at or above the proper level. If low, refer to «Brake Fluid Loss»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system__brake-fluid-loss) .
- Ignition ON, observe the scan tool IPC Brake Fluid parameter. The reading should be OK.
Circuit/System Testing
- Ignition OFF, disconnect the harness connector at the brake fluid level switch.
- Test for less than 10 ohm between the ground circuit terminal A and ground. If greater than the specified range, test the ground circuit for an open/high resistance.
- Ignition ON, verify the scan tool IPC Brake Fluid parameter is Ok. If not the specified value, test the signal circuit for a short to ground. If the circuit tests normal, replace the IPC.
- Install a 3A fused jumper wire between the signal circuit terminal B and ground. Verify the scan tool IPC Brake Fluid parameter is Low. If not the specified value, test the signal circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the IPC.
- If all circuits test normal, test or replace the brake fluid level switch.
Repair Procedures
- «Brake Fluid Level Indicator Switch Replacement (Two-mode Hybrid)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) or «Brake Fluid Level Indicator Switch Replacement (JD9, JH6)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system)
- «Control Module References»(/cadillac/escalade/gmt900-2006-2014/remont/communication-devices/#programming-and-setup-all-systems__control-module-references) for IPC replacement, setup, and programming
- Perform the «Diagnostic System Check - Vehicle»(/cadillac/escalade/gmt900-2006-2014/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures) prior to using this diagnostic procedure.
- Review «Strategy Based Diagnosis»(/cadillac/escalade/gmt900-2006-2014/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__strategy-based-diagnosis) for an overview of the diagnostic approach.
- «Diagnostic Procedure Instructions»(/cadillac/escalade/gmt900-2006-2014/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__diagnostic-procedure-instructions) provides an overview of each diagnostic category.
| Circuit | Short to Ground | Open/High Resistance | Short to Voltage | Signal Performance |
| Power Brake Booster High Control | C0299 00 | C0299 00 | C0299 00 | C0299 5A |
| Power Brake Booster Low Control | | C0299 00 | C0299 00 | C0299 5A |
The electronic brake control module (EBCM) provides power and ground circuits to the power brake booster actuator. The power brake booster actuator converts electrical inputs into a mechanical force to apply the brake booster to assist the driver as necessary in stability control. The EBCM monitors the vacuum level in the power brake booster, and will set a DTC if the vacuum is too low.
- Ignition ON.
- Ignition voltage is greater than10 volts.
- Ignition ON.
- Engine Running.
- Ignition voltage is greater than 10 volts.
C0299 00
The EBCM detects a short to ground, open/high resistance or a short to voltage on the power brake booster actuator control circuits.
C0299 5A
- No vacuum is detected in the power brake booster for approximately 10 seconds after start-up.
- Low vacuum is detected in the power brake booster for approximately 60 seconds or longer after start-up, or is detected while driving.
- The EBCM disables the active vacuum booster for the duration of the ignition cycle.
- A DIC message and/or a warning indicator may be displayed.
- The condition for the DTC is no longer present.
- The EBCM clears the history DTC when a current DTC is not detected in 100 consecutive drive cycles.
Connector End View Reference
Description and Operation
Electrical Information Reference
- «Circuit Testing»(/cadillac/escalade/gmt900-2006-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__circuit-testing)
- «Connector Repairs»(/cadillac/escalade/gmt900-2006-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__connector-repairs)
- «Testing for Intermittent Conditions and Poor Connections»(/cadillac/escalade/gmt900-2006-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__testing-for-intermittent-conditions-and-poor)
- «Wiring Repairs»(/cadillac/escalade/gmt900-2006-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__wiring-repairs)
- Ignition OFF, disconnect the harness connector from the power brake booster actuator.
- Test for less than 25k ohms of resistance between the harness connector terminal 5 and ground. If greater than 25k ohms, test the ground circuit for an open/high resistance.
- Connect a test lamp between the actuator harness connector terminal 1 and terminal 5.
- Ignition ON, command the Active Brake Booster to ON and OFF with a scan tool. If the test lamp remains OFF during the commands, test for a short to ground or an open/high resistance on either control circuit. If the circuits test normal, replace the electronic brake control module EBCM. If the test lamp is always ON, test the control circuits for a short to battery positive. If the circuit tests normal, locate and repair the source of the vacuum leak.
- If all circuits test normal, test or replace the vacuum brake booster assembly.
- If all circuits test normal, and no vacuum leaks were found, replace the electronic brake control module (EBCM).
Verify DTC C0299 5A is not set.
- If the DTC is set, repair the source of the vacuum leak. Refer to «Brake Assist System Diagnosis»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system__brake-assist-system-diagnosis) .
Component Testing
- Ignition OFF, disconnect the harness connector at the power brake booster actuator.
- Test for infinite ohms of resistance between the actuator terminal 1 and ground. If less than infinite ohms, replace the vacuum brake booster assembly.
- Test for 2-3 ohms of resistance between terminals 1 and 5 at the power brake booster actuator.
- If the test is infinite resistance, replace the vacuum brake booster assembly.
- «Power Vacuum Brake Booster Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system)
- «Control Module References»(/cadillac/escalade/gmt900-2006-2014/remont/communication-devices/#programming-and-setup-all-systems__control-module-references) for EBCM replacement, setup, and programming
- Perform the «Diagnostic System Check - Vehicle»(/cadillac/escalade/gmt900-2006-2014/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures) prior to using this diagnostic procedure.
- Review «Strategy Based Diagnosis»(/cadillac/escalade/gmt900-2006-2014/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__strategy-based-diagnosis) for an overview of the diagnostic approach.
- «Diagnostic Procedure Instructions»(/cadillac/escalade/gmt900-2006-2014/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__diagnostic-procedure-instructions) provides an overview of each diagnostic category.
| Circuit | Short to Ground | Open/High Resistance | Short to Voltage | Signal Performance |
| Brake Booster Vacuum Sensor 5 V Reference | C1100 00, C0710 00 | C1100 00 | C1100 00, C0710 00 | |
| Steering Angle Sensor 5 V Reference | C1100 00, C0710 00 | C0455 00 | C1100 00, C0710 00 | |
| Signal | C1100 00 | C1100 00 | C1100 00 | |
| Low Reference | | C1100 00 | | |
The electronic brake control module (EBCM) provides a 5 V reference circuit to the brake booster vacuum sensor and the steering angle sensor. The brake booster vacuum sensor converts the change in vacuum levels in the brake booster into a signal voltage ranging from 0.13 - 3.30 V and is monitored by EBCM.
The brake booster sensor signal voltage is not within 0.13 - 3.30 V for more than 1 second.
- The condition for the DTC is no longer present.
- The EBCM clears the history DTC when a current DTC is not detected in 100 consecutive drive cycles.
Connector End View Reference
Description and Operation
Electrical Information Reference
- «Circuit Testing»(/cadillac/escalade/gmt900-2006-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__circuit-testing)
- «Connector Repairs»(/cadillac/escalade/gmt900-2006-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__connector-repairs)
- «Testing for Intermittent Conditions and Poor Connections»(/cadillac/escalade/gmt900-2006-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__testing-for-intermittent-conditions-and-poor)
- «Wiring Repairs»(/cadillac/escalade/gmt900-2006-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__wiring-repairs)
Note. If only DTC C1100 is set refer to Only DTC C1100 Set, if both DTC C0710 and C1100 are set, refer to Both DTC C0710 and C1100 Set.
- Ignition OFF, disconnect the harness connector at the brake booster vacuum sensor.
- Wait for 60 seconds, test for less than 11 ohms between the low reference circuit terminal 2 and ground. If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the EBCM.
- Ignition ON, test for 4.8 - 5.2 V between the 5 V reference circuit terminal 3 and ground. If less than the specified range, test the 5 V reference circuit for an open/high resistance. If the circuit tests normal, replace the replace the EBCM. If greater than the specified range, test the 5 V reference circuit for a short to B+. If the circuit tests normal, replace the EBCM.
- Test for 4.8 - 5.2 V between the 5 V reference circuit terminal 3 and the signal circuit terminal 1. If less than the specified range, test the signal circuit for an open/high resistance. If the circuit tests normal, replace the EBCM. If greater than the specified range, test the signal circuit for a short to B+. If the circuit tests normal, replace the EBCM.
- Ignition OFF, disconnect the harness connector at the EBCM.
- Test for infinite resistance between the signal circuit terminal 1 and ground. If not the specified value, test the signal circuit for a short to ground.
- If all circuits test normal, test or replace the brake booster vacuum sensor.
Both DTC C0710 and C1100 Set
- Ignition OFF, disconnect the harness connector at the brake booster vacuum sensor and the steering angle sensor.
- Ignition ON, test for 4.8 - 5.2 V between the 5 V reference circuit terminals listed below and ground. Terminal 3 at the brake booster vacuum sensor Terminal 1 at the steering angle sensor If less than the specified range, test both 5 V reference circuits for a short to ground. If the circuit tests normal, replace the EBCM. If greater than the specified range, test both 5 V reference circuits for a short to voltage. If the circuits test normal, replace the EBCM.
- If all circuits test normal, test or replace the brake booster vacuum sensor or steering angle sensor as required.
- «Power Brake Booster Vacuum Sensor Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system)
- «Steering Wheel Position Sensor Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/steering-column-switches/#steering-wheel-steering-column)
- «Control Module References»(/cadillac/escalade/gmt900-2006-2014/remont/communication-devices/#programming-and-setup-all-systems__control-module-references) for EBCM replacement, setup, and programming
Symptoms - Hydraulic Brakes
Visual/Physical Inspection
- Inspect for aftermarket devices which could affect the operation of the Hydraulic Brake System. Refer to «Checking Aftermarket Accessories»(/cadillac/escalade/gmt900-2006-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__checking-aftermarket-accessories) .
- Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom.
Intermittent
Symptom List
Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom
- «Brake Warning Indicator Malfunction»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system)
- «Brake Pulsation»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system__brake-pulsation)
- «Brake System Noise»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system__brake-system-noise)
- «Braking Action Uneven - Pulls to One Side»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system)
- «Braking Action Uneven - Front to Rear»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system)
- «Brake Pedal Excessive Travel (Non-Hybrid)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system__brake-pedal-excessive-travel-non-hybrid) or «Brake Pedal Excessive Travel (Two-mode Hybrid)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system__brake-pedal-excessive-travel-two-mode-hybrid)
- «Brake Pedal Excessive Effort»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system__brake-pedal-excessive-effort)
- «Brakes Drag»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system__brakes-drag)
- «Brake System Slow Release»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system__brake-system-slow-release)
- «Brake Fluid Loss»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system__brake-fluid-loss)
- «Brakes Self Apply When Turning Steering Wheel»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system__brakes-self-apply-when-turning-steering)
- «Hydraulic Brake System Diagnosis»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system)
- «Brake Assist System Diagnosis»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system__brake-assist-system-diagnosis)
- Perform the «Diagnostic System Check - Vehicle»(/cadillac/escalade/gmt900-2006-2014/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures) prior to using this diagnostic procedure.
- Review «Strategy Based Diagnosis»(/cadillac/escalade/gmt900-2006-2014/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__strategy-based-diagnosis) for an overview of the diagnostic approach.
- «Diagnostic Procedure Instructions»(/cadillac/escalade/gmt900-2006-2014/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__diagnostic-procedure-instructions) provides an overview of each diagnostic category.
| Circuit | Short to Ground | Open/High Resistance | Short to Voltage | Signal Performance |
| Brake Fluid Level Signal | C0267 00 | 1 | 1 | |
| Park Brake Signal | 1 | 1 | 1 | |
| Ground | | 1 | | |
| 1. Brake Warning Indicator Malfunction |
The instrument panel cluster (IPC) sees the brake fluid level switch input opens and illuminates the Red Brake Warning indicator. The body control module (BCM) sees the park brake switch input grounded, it sends a serial data message to the IPC requesting illumination of the Red Brake Warning indicator.
Connector End View Reference
Description and Operation
Electrical Information Reference
- «Circuit Testing»(/cadillac/escalade/gmt900-2006-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__circuit-testing)
- «Connector Repairs»(/cadillac/escalade/gmt900-2006-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__connector-repairs)
- «Testing for Intermittent Conditions and Poor Connections»(/cadillac/escalade/gmt900-2006-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__testing-for-intermittent-conditions-and-poor)
- «Wiring Repairs»(/cadillac/escalade/gmt900-2006-2014/remont/ignition-switchsteering-lock/#wiring-systems-and-power-management-diagnostic-information-and-procedures__wiring-repairs)
- Verify the park brake is released and the brake fluid is at or above the proper level. If low, refer to «Brake Fluid Loss»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system__brake-fluid-loss) .
- Command the IPC display test with a scan tool, the warning indicator should turn ON. If the red brake warning indicator does not illuminate, replace the IPC.
- Ignition ON, observe the scan tool BCM Park Brake Switch parameter while applying and releasing the park brake. The parameter should cycle between Applied and Release. If the parameter does not cycle between the specified values, refer to Park Brake Switch Malfunction.
- Observe the scan tool IPC Brake Fluid parameter. The reading should be OK. If not the specified value, refer to Brake Fluid Level Switch Malfunction.
Park Brake Switch Malfunction
- Ignition OFF, disconnect the harness connector at the park brake switch.
- Ignition ON, verify the scan tool BCM Park Brake Switch parameter is Released. If not the specified value, test the signal circuit terminal A for a short to ground. If the circuit tests normal, replace the BCM.
- Install a 3A fused jumper wire between the signal circuit terminal A and ground. Verify the scan tool BCM Park Brake Switch parameter is Applied. If not the specified value, test the signal circuit for a short to voltage or an open/high resistance.
- If all circuits test normal, test or replace the park brake switch.
Brake Fluid Level Switch Malfunction
- Ignition OFF, disconnect the harness connector at the brake fluid level switch.
- Test for less than 1 ohm between the ground circuit terminal A and ground. If greater than the specified range, test the ground circuit for an open/high resistance.
- Ignition ON, verify the scan tool IPC Brake Fluid parameter is Ok. If not the specified value, test the signal circuit for a short to ground. If the circuit tests normal, replace the IPC.
- Install a 3A fused jumper wire between the signal circuit terminal B and ground. Verify the scan tool IPC Brake Fluid parameter is Low. If not the specified value, test the signal circuit for a short to voltage or an open/high resistance. If the circuit tests normal, replace the IPC.
- If all circuits test normal, test or replace the brake fluid level switch.
Park Brake Switch Malfunction
- Ignition OFF, disconnect the harness connector at the park brake switch.
- Test for infinite resistance between the signal terminal A and ground with the park brake released. If less than the specified value, replace the park brake switch.
- Test for less than 1 ohm between the signal terminal A and ground with the park brake applied. If greater than the specified range, replace the park brake switch.
Brake Fluid Level Switch Malfunction
- Ignition OFF, disconnect the harness connector at the brake fluid level switch.
- Test for infinite resistance between the ground terminal A and the signal terminal B. If less than the specified value, replace the brake fluid level switch.
- «Brake Fluid Level Indicator Switch Replacement (Two-mode Hybrid)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) or «Brake Fluid Level Indicator Switch Replacement (JD9, JH6)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system)
- «Parking Brake Indicator Switch Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/parking-brake-system/#parking-brake-system)
- «Control Module References»(/cadillac/escalade/gmt900-2006-2014/remont/communication-devices/#programming-and-setup-all-systems__control-module-references) for BCM and IPC replacement, setup, and programming
Brake Pulsation
| Step | Action | Yes | No |
| DEFINITION: Fluctuation or pulsation is felt through the brake pedal, steering wheel, seat, floor, and/or in the vehicle ONLY when braking. |
| 1 | Were you sent here from the Hydraulic Brake Symptom table? | Go to Step 2 | Go to Symptoms - Hydraulic Brakes |
| 2 | Inspect the disc brake system for the following conditions. Excessive thickness variation of rotor friction surfaces Excessive assembled lateral runout (LRO) of rotor friction surfaces Hard spots, heat checks, bluing discoloration of rotor friction surfaces; possibly due to brake drag Excessive corrosion of rotor friction surfaces; including red, gray or black oxidation Loose, damaged or missing caliper or lining hardware Bent or damaged caliper or mounting component Excessive LRO of wheel hub/axle flange; due to damage and/or loose or excessively worn bearings Adjust, repair or replace components as necessary. Refer to Disc Brake System Diagnosis . Did you find and correct a condition? | Go to Step 3 | Go to Symptoms - Hydraulic Brakes |
| 3 | Install or connect components that were removed or disconnected during diagnosis. Road test the vehicle in order to confirm proper operation. Refer to Brake System Vehicle Road Test . Is the condition still present? | Go to Step 2 | System OK |
Brake System Noise
| Step | Action | Yes | No |
| DEFINITION: Vehicle exhibits abnormal noise when braking; vehicle may exhibit abnormal noise during motion just after brake pedal release. |
| 1 | Were you sent here from the Hydraulic Brake Symptom table? | Go to Step 2 | Go to Symptoms - Hydraulic Brakes |
| 2 | Inspect the disc brake system for the following conditions. Lining wear indicator contact with rotor Debris trapped between rotor and splash shield or backing plate; and/or debris trapped between rotor and linings Contaminated linings Aftermarket linings Glazed linings Distorted, cracked or damaged linings Excessively worn linings Damaged or excessively worn caliper hardware and/or lining hardware Incorrectly installed, loose or missing caliper hardware and/or lining hardware Lack of lubrication or excessive corrosion on metal to metal contact surfaces Bent or damaged splash shield or backing plate Hard spots, heat checks, blueing discoloration of rotor friction surfaces Glazed rotor friction surfaces Bent or damaged caliper or mounting component Adjust, repair or replace components as necessary. Refer to Disc Brake System Diagnosis . Did you find and correct a condition? | Go to Step 9 | Go to Step 3 |
| 3 | Inspect the brake assist system for the following conditions. Lack of lubrication or excessively worn pushrod or pedal pivots or pivot bushings Bent or damaged pedal pushrod, pedal, or pedal bracket Damaged or improperly operating vacuum booster and/or check valve, if equipped Low power steering fluid level, if equipped with hydraulic boost Improperly tensioned, excessively worn or damaged power steering belt, if equipped with hydraulic boost Restricted return hose from hydraulic booster, if equipped Improperly operating hydraulic booster, if equipped Improperly functioning power steering system, if equipped with a hydraulic booster assembly Contaminated power steering fluid, if equipped with hydraulic boost Adjust, repair or replace components as necessary. Refer to Brake Assist System Diagnosis . Did you find and correct a condition? | Go to Step 9 | Go to Step 4 |
| 4 | Inspect the hydraulic brake system for the following conditions. Improper operation of caliper pistons Contaminated brake fluid Adjust, repair or replace components as necessary. Refer to Hydraulic Brake System Diagnosis . Did you find and correct a condition? | Go to Step 9 | Go to Step 5 |
| 5 | Is the vehicle equipped with a drum-in-rotor type of park brake system? | Go to Step 6 | Go to Step 9 |
| 6 | Ensure the park brake shoes are not adjusted too tightly, possibly causing a noise under certain conditions. Are the park brake shoes adjusted too tightly? | Go to Step 7 | Go to Step 9 |
| 7 | Clean and inspect the park brake shoes for excessive wear and/or damage. Inspect the drum portion of the rotors for excessive wear, blueing discoloration, heat spots, and excessive radial runout. If any of these conditions are present, replace the affected components. Adjust the park brake system. Did you find and correct a condition? | Go to Step 9 | Go to Step 8 |
| 8 | Inspect the park brake system for proper operation. Refer to Park Brake System Diagnosis . Did you find and correct a condition? | Go to Step 9 | Go to Symptoms - Hydraulic Brakes |
| 9 | Install or connect components that were removed or disconnected during diagnosis. Road test the vehicle in order to confirm proper operation. Refer to Brake System Vehicle Road Test . Is the condition still present? | Go to Step 2 | System OK |
Test Description
The numbers below refer to the step numbers on the diagnostic table.
- 4: Suspension components that are not operating properly may cause a disturbance to the vehicle during application of the brake system.
- 5: Steering components that are not operating properly may cause a disturbance to the vehicle during application of the brake system.
| Step | Action | Yes | No |
| DEFINITION: Vehicle pulls to one side only when braking. |
| 1 | Were you sent here from the Hydraulic Brake Symptom table? | Go to Step 2 | Go to Symptoms - Hydraulic Brakes |
| 2 | Inspect the hydraulic brake system for the following conditions. Kinked, pinched or damaged brake pipe or flexible brake hose Sticking or improperly operating caliper piston Brake fluid leak Adjust, repair or replace components as necessary. Refer to Hydraulic Brake System Diagnosis . Did you find and correct a condition? | Go to Step 6 | Go to Step 3 |
| 3 | Inspect the disc brake system for the following conditions. Contaminated linings Glazed linings Distorted, cracked or damaged linings on one side Loose, damaged or missing caliper hardware and/or lining hardware Incorrect linings on one side Hard spots, heat checks, blueing discoloration of rotor friction surfaces; possibly due to brake drag Glazed rotor friction surfaces Bent or damaged caliper or mounting component Adjust, repair or replace components as necessary. Refer to Disc Brake System Diagnosis . Did you find and correct a condition? | Go to Step 6 | Go to Step 4 |
| 4 | Inspect the suspension system for the following conditions. Incorrect tire pressures Loose suspension component connections Excessively worn or damaged suspension components Adjust, repair or replace components as necessary. Refer to Symptoms - Suspension General Diagnosis . Did you find and correct a condition? | Go to Step 6 | Go to Step 5 |
| 5 | Inspect the steering system for the following conditions. Loose steering component connections Excessively worn or damaged steering components Adjust, repair or replace components as necessary. Did you find and correct a condition? | Go to Step 6 | Go to Symptoms - Hydraulic Brakes |
| 6 | Install or connect components that were removed or disconnected during diagnosis. Road test the vehicle in order to confirm proper operation. Refer to Brake System Vehicle Road Test . Is the condition still present? | Go to Step 2 | System OK |
Test Descriptions
The number below refers to the step number on the diagnostic table.
- 4: Suspension components that are not operating properly may cause a disturbance to the vehicle during application of the brake system.
| Step | Action | Yes | No |
| DEFINITION: Braking action or stopping force sensitive or grabbing and/or more pronounced at the front or at the rear axle. Sensitive or grabbing brakes: Excessive brake jump-in force relative to brake pedal input. |
| 1 | Were you sent here from the Hydraulic Brake Symptom table? | Go to Step 2 | Go to Symptoms - Hydraulic Brakes |
| 2 | Inspect the hydraulic brake system for the following conditions: Improper operation of caliper pistons Kinked, pinched or damaged brake pipe or flexible brake hose Brake fluid leak Improperly functioning proportion valve, if equipped Improper operation of dynamic rear proportion (DRP) system, if equipped Adjust, repair or replace components as necessary. Refer to Hydraulic Brake System Diagnosis . Did you find and correct a condition? | Go to Step 6 | Go to Step 3 |
| 3 | Inspect the disc brake system for the following conditions: Contaminated linings Glazed linings Distorted, cracked or damaged linings Excessively worn linings Aftermarket linings Damaged or excessively worn caliper hardware and/or lining hardware Hard spots, heat checks, blueing discoloration of rotor friction surfaces Glazed rotor friction surfaces Adjust, repair or replace components as necessary. Refer to Disc Brake System Diagnosis . Did you find and correct a condition? | Go to Step 6 | Go to Step 4 |
| 4 | Inspect the suspension system for the following conditions: Loose suspension component connections Excessively worn or damaged suspension components Adjust, repair or replace components as necessary. Refer to Symptoms - Suspension General Diagnosis . Did you find and correct a condition? | Go to Step 6 | Go to Step 5 |
| 5 | Inspect the brake assist system for the following conditions: Binding, bent or damaged pedal pushrod, pedal, or pedal bracket Damaged or improperly operating vacuum booster, if equipped Damaged or improperly operating hydraulic booster, if equipped Adjust, repair or replace components as necessary. Refer to Brake Assist System Diagnosis . Did you find and correct a condition? | Go to Step 6 | Go to Symptoms - Hydraulic Brakes |
| 6 | Install or connect components that were removed or disconnected during diagnosis. Road test the vehicle in order to confirm proper operation. Refer to Brake System Vehicle Road Test . Is the condition still present? | Go to Step 2 | System OK |
Brake Pedal Excessive Travel (Non-Hybrid)
| Step | Action | Yes | No |
| DEFINITION: Brake pedal travels further than expected to obtain firm pedal and/or firm pedal cannot be obtained, pedal fades away, or pedal is spongy. |
| 1 | Were you sent here from the Hydraulic Brake Symptom table? | Go to Step 2 | Go to Symptoms - Hydraulic Brakes |
| 2 | Inspect the travel and feel of brake pedal applies. Perform the following: Apply the brake pedal several times to fully deplete the power reserve. With power reserve depleted, apply the brake pedal with light, steady pressure and hold for 15 seconds. Observe pedal travel and feel. Apply the brake pedal with light, steady pressure, then without pumping the pedal, reduce pressure and reapply pressure several times. Observe pedal travel and feel for each apply. Apply the brake pedal slowly, then release and apply the pedal quickly. Observe pedal travel and feel for each apply. Did you complete the brake pedal travel and feel inspections? | Go to Step 3 | |
| 3 | Inspect the hydraulic brake system for the conditions listed, based on the following symptoms observed during the pedal travel and feel inspections: Pedal feel was spongy Air in hydraulic system External brake fluid leaks Soft, weak or damaged hydraulic hoses; expanding under pressure Pedal fell away and/or traveled to or almost to floor External brake fluid leaks Poor brake fluid quality; low boiling point Internal brake fluid leaks; improperly functioning master cylinder Pedal was somewhat firm then dropped slightly, or pedal rose with successive applies, or pedal travel was different between slow and quick applies Internal brake fluid leaks; improperly functioning master cylinder Poor brake fluid quality; low boiling point Pedal returned to rest slowly after any of the applies Internally damaged flexible brake hoses; hindering fluid return Binding caliper pistons Internal brake fluid leaks; improperly functioning master cylinder Repair or replace components as necessary. Refer to Hydraulic Brake System Diagnosis . Re-inspect brake pedal apply travel and feel. Did you find and correct a condition? | Go to Step 8 | Go to Step 4 |
| 4 | Inspect the disc brake system for the following conditions: Cracked, excessively worn or damaged linings Cracked, excessively worn or damaged rotors Improperly operating, binding or damaged caliper hardware and/or lining hardware Loose or missing caliper hardware and/or lining hardware Excessive assembled lateral runout (LRO) of rotor friction surfaces Bent or damaged caliper or mounting component Adjust, repair or replace components as necessary. Refer to Disc Brake System Diagnosis . Re-inspect brake pedal apply travel and feel. Did you find and correct a condition? | Go to Step 8 | Go to Step 5 |
| 5 | Inspect for proper brake pedal travel. Refer to Brake Pedal Travel Measurement and Inspection (Non-Hybrid) or Brake Pedal Travel Measurement and Inspection (Two-mode Hybrid) . Is the brake pedal travel distance within the acceptable limits? | Go to Step 7 | Go to Step 6 |
| 6 | Inspect for worn, missing, misaligned, bent or damaged brake pedal system components. For the brake pedal pushrod component inspection, refer to Brake Pedal Pushrod Inspection . Inspect the brake pedal bushings for binding, excessive wear and/or damage and inspect the brake pedal for a misaligned, bent, and/or damaged condition. Replace the brake pedal system components that are worn, missing, misaligned, bent or damaged. Did you find and replace any worn, missing, misaligned, bent or damaged brake pedal system components? | Go to Step 8 | Go to Step 7 |
| 7 | Inspect the brake assist system for the following conditions: Vacuum leaks and/or improperly operating check valve, if equipped with vacuum assist Power steering fluid leaks, if equipped with hydraulic power assist Damaged or improperly operating brake booster assembly Adjust, repair or replace components as necessary. Refer to Brake Assist System Diagnosis . Did you find and correct a condition? | Go to Step 8 | Go to Symptoms - Hydraulic Brakes |
| 8 | Install or connect components that were removed or disconnected during diagnosis. Road test the vehicle in order to confirm proper operation. Refer to Brake System Vehicle Road Test . Is the condition still present? | Go to Step 2 | System OK |
Brake Pedal Excessive Travel (Two-mode Hybrid)
| Step | Action | Yes | No |
| DEFINITION: Brake pedal travels further than expected to obtain firm pedal and/or firm pedal cannot be obtained, pedal fades away, or pedal is spongy. |
| 1 | Were you sent here from the Hydraulic Brake Symptom table? | Go to Step 2 | Go to Symptoms - Hydraulic Brakes |
| 2 | Inspect the travel and feel of brake pedal applies. Perform the following: Ensure the ignition is OFF for at least 60 seconds to depressurize and deplete the power reserve. With the ignition OFF, apply the brake pedal several times to verify the power reserve is fully depleted. With power reserve depleted, apply the brake pedal with light, steady pressure and hold for 15 seconds. Observe pedal travel and feel. Apply the brake pedal with light, steady pressure, then without pumping the pedal, reduce pressure and reapply pressure several times. Observe pedal travel and feel for each apply. Apply the brake pedal slowly, then release and apply the pedal quickly. Observe pedal travel and feel for each apply. Did you complete the brake pedal travel and feel inspections? | Go to Step 3 | |
| 3 | Inspect the hydraulic brake system for the conditions listed, based on the following symptoms observed during the pedal travel and feel inspections: Pedal feel was spongy Air in hydraulic system External brake fluid leaks Soft, weak or damaged hydraulic hoses; expanding under pressure Pedal fell away and/or traveled to or almost to floor External brake fluid leaks Poor brake fluid quality; low boiling point Internal brake fluid leaks; improperly functioning master cylinder Pedal was somewhat firm then dropped slightly, or pedal rose with successive applies, or pedal travel was different between slow and quick applies Internal brake fluid leaks; improperly functioning master cylinder Poor brake fluid quality; low boiling point Pedal returned to rest slowly after any of the applies Internally damaged flexible brake hoses; hindering fluid return Binding caliper pistons Internal brake fluid leaks; improperly functioning master cylinder Repair or replace components as necessary. Refer to Hydraulic Brake System Diagnosis . Re-inspect brake pedal apply travel and feel. Did you find and correct a condition? | Go to Step 9 | Go to Step 4 |
| 4 | Inspect the disc brake system for the following conditions: Cracked, excessively worn or damaged linings Cracked, excessively worn or damaged rotors Improperly operating, binding or damaged caliper hardware and/or lining hardware Loose or missing caliper hardware and/or lining hardware Excessive assembled lateral runout (LRO) of rotor friction surfaces Bent or damaged caliper or mounting component Adjust, repair or replace components as necessary. Refer to Disc Brake System Diagnosis . Re-inspect brake pedal apply travel and feel. Did you find and correct a condition? | Go to Step 9 | Go to Step 5 |
| 5 | Inspect for proper brake pedal travel. Refer to Brake Pedal Travel Measurement and Inspection (Non-Hybrid) or Brake Pedal Travel Measurement and Inspection (Two-mode Hybrid) . Is the brake pedal travel distance within the acceptable limits? | Go to Step 8 | Go to Step 6 |
| 6 | Inspect for worn, missing, misaligned, bent or damaged brake pedal system components. For the brake pedal pushrod component inspection, refer to Brake Pedal Pushrod Inspection . Inspect the brake pedal bushings for binding, excessive wear and/or damage and inspect the brake pedal for a misaligned, bent, and/or damaged condition. Replace the brake pedal system components that are worn, missing, misaligned, bent or damaged. Did you find and replace any worn, missing, misaligned, bent or damaged brake pedal system components? | Go to Step 9 | Go to Step 7 |
| 7 | Replace the brake master cylinder assembly. Inspect the brake pedal travel. Refer to Brake Pedal Travel Measurement and Inspection (Non-Hybrid) or Brake Pedal Travel Measurement and Inspection (Two-mode Hybrid) . Did you find and correct a condition? | Go to Step 9 | Go to Step 8 |
| 8 | Inspect the brake assist system for the following conditions: Internal fluid leaks and/or restrictions within the brake modulator assembly Damaged or improperly operating brake modulator assembly Adjust, repair or replace components as necessary. Refer to Brake Assist System Diagnosis . Did you find and correct a condition? | Go to Step 9 | Go to Symptoms - Hydraulic Brakes |
| 9 | Install or connect components that were removed or disconnected during diagnosis. Road test the vehicle in order to confirm proper operation. Refer to Brake System Vehicle Road Test . Is the condition still present? | Go to Step 2 | System OK |
Brake Pedal Excessive Effort
| Step | Action | Yes | No |
| DEFINITION: Brake pedal requires an increased amount of input from the driver to obtain good braking action and/or stopping distance is increased. |
| 1 | Were you sent here from the Hydraulic Brake Symptom table? | Go to Step 2 | Go to Symptoms - Hydraulic Brakes |
| 2 | Inspect the brake assist system for the following conditions: Vacuum leaks, if equipped with vacuum power assist Power steering fluid leaks, if equipped with hydraulic power assist Lack of lubrication, binding or excessively worn pushrod or pedal pivots or pivot bushings Bent or damaged pedal pushrod, pedal, or pedal bracket Damaged or improperly operating brake booster assembly Adjust, repair or replace components as necessary. Refer to Brake Assist System Diagnosis . Did you find and correct a condition? | Go to Step 5 | Go to Step 3 |
| 3 | Inspect the hydraulic brake system for the following conditions: Binding caliper pistons Internally damaged flexible brake hoses; hindering fluid flow External brake fluid leaks Kinked or damaged flexible brake hoses and/or pipes Internal brake fluid leaks; improperly operating master cylinder Poor brake fluid quality; low boiling point Adjust, repair or replace components as necessary. Refer to Hydraulic Brake System Diagnosis . Did you find and correct a condition? | Go to Step 5 | Go to Step 4 |
| 4 | Inspect the disc brake system for the following conditions: Excessively worn linings Glazed linings Cracked, distorted or damaged linings Contaminated linings Binding, damaged or excessively worn caliper hardware and/or lining hardware Lack of lubrication or excessive corrosion on metal to metal contact surfaces Excessively worn or corroded rotor friction surfaces Glazed rotor friction surfaces Hard spots, heat checks, blueing discoloration of rotor friction surfaces Adjust, repair or replace components as necessary. Refer to Disc Brake System Diagnosis . Did you find and correct a condition? | Go to Step 5 | Go to Symptoms - Hydraulic Brakes |
| 5 | Install or connect components that were removed or disconnected during diagnosis. Road test the vehicle in order to confirm proper operation. Refer to Brake System Vehicle Road Test . Is the condition still present? | Go to Step 2 | System OK |
Brakes Drag
| Step | Action | Yes | No |
| DEFINITION: Brake system does not fully release or has delayed release; vehicle motion may be hindered by brake system without applying brakes. |
| 1 | Were you sent here from the Hydraulic Brake Symptom table? | Go to Step 2 | Go to Symptoms - Hydraulic Brakes |
| 2 | Is the vehicle equipped with an adjustable stop lamp switch and/or an adjustable cruise control release switch? | Go to Step 3 | Go to Step 4 |
| 3 | Inspect the stop lamp switch for proper adjustment to ensure that the brake pedal is fully releasing. Inspect the cruise control release switch, if equipped, for proper adjustment to ensure that the brake pedal is fully releasing. Did you find and correct a condition? | Go to Step 14 | Go to Step 4 |
| 4 | Is the vehicle equipped with a drum-in-rotor type of park brake system? | Go to Step 5 | Go to Step 7 |
| 5 | Ensure the park brake shoes are not adjusted too tightly, possibly causing drag under certain conditions. Are the park brake shoes adjusted too tightly? | Go to Step 6 | Go to Step 7 |
| 6 | Clean and inspect the park brake shoes for excessive wear and/or damage. Inspect the drum portion of the rotors for excessive wear, blueing discoloration and heat spots. If any of these conditions are present, replace the affected components. Adjust the park brake system. Did you find and correct a condition? | Go to Step 14 | Go to Step 7 |
| 7 | Inspect the park brake system for proper operation. Refer to Park Brake System Diagnosis . Did you find and correct a condition? | Go to Step 14 | Go to Step 8 |
| 8 | Inspect the disc brake system for the following conditions: Binding, incorrectly installed or missing caliper hardware and/or lining hardware-Ensure free movement of linings and of caliper, if equipped with sliding type caliper Lack of lubrication or excessive corrosion on metal to metal contact surfaces Distorted or damaged linings Damaged or excessively worn caliper hardware and/or lining hardware Bent or damaged caliper or mounting component Adjust, repair or replace components as necessary. Refer to Disc Brake System Diagnosis . Did you find and correct a condition? | Go to Step 14 | Go to Step 9 |
| 9 | Separate the brake booster pushrod from the brake pedal. Inspect the brake corners to determine if the brake drag condition is still present. Do the brake corners still exhibit the brake drag condition? | Go to Step 11 | Go to Step 10 |
| 10 | Inspect the pushrod for improper positioning and/or damage. Correctly position or replace the pushrod if necessary. Inspect the brake pedal assembly for damage and replace if necessary. Did you complete the repair or replacement? | Go to Step 14 | |
| 11 | For vacuum boost systems, disconnect the vacuum check valve from the booster to relieve vacuum reserve. Separate the master cylinder from the brake booster. Do not disconnect any brake pipes. Inspect the brake corners to determine if the brake drag condition is still present. Do the brake corners still exhibit the brake drag condition? | Go to Step 13 | Go to Step 12 |
| 12 | Replace the brake booster assembly. Did you complete the replacement? | Go to Step 14 | |
| 13 | Inspect the hydraulic brake system for the following conditions. Improper operation of caliper pistons Contaminated brake fluid Internally damaged flexible brake hoses; hindering brake release Damaged or improperly operating master cylinder Adjust, repair or replace components as necessary. Refer to Hydraulic Brake System Diagnosis . Did you find and correct a condition? | Go to Step 14 | Go to Symptoms - Hydraulic Brakes |
| 14 | Install or connect components that were removed or disconnected during diagnosis. Road test the vehicle in order to confirm proper operation. Refer to Brake System Vehicle Road Test . Is the condition still present? | Go to Step 2 | System OK |
Brake System Slow Release
| Step | Action | Yes | No |
| DEFINITION: Brake system releases and returns to rest slowly; vehicle motion is hindered by brake system briefly after release of brake pedal. |
| 1 | Were you sent here from the Hydraulic Brake Symptom table? | Go to Step 2 | Go to Symptoms - Hydraulic Brakes |
| 2 | Inspect the hydraulic brake system for the following conditions: Improper operation of caliper pistons Internally damaged flexible brake hoses; hindering brake release Contaminated brake fluid Damaged or improperly operating master cylinder Adjust, repair or replace components as necessary. Refer to Hydraulic Brake System Diagnosis . Did you find and correct a condition? | Go to Step 5 | Go to Step 3 |
| 3 | Inspect the brake assist system for the following conditions: Binding, bent or damaged pedal pushrod, pedal, or pedal bracket Damaged or improperly operating vacuum booster, if equipped Restricted return hose from hydraulic booster, if equipped Damaged or improperly operating hydraulic booster, if equipped Adjust, repair or replace components as necessary. Refer to Brake Assist System Diagnosis . Did you find and correct a condition? | Go to Step 5 | Go to Step 4 |
| 4 | Inspect the disc brake system for the following conditions: Damaged or excessively worn caliper hardware and/or lining hardware Distorted or damaged linings Lack of lubrication or excessive corrosion on metal to metal contact surfaces Bent or damaged caliper or mounting component Adjust, repair or replace components as necessary. Refer to Disc Brake System Diagnosis . Did you find and correct a condition? | Go to Step 5 | Go to Symptoms - Hydraulic Brakes |
| 5 | Install or connect components that were removed or disconnected during diagnosis. Road test the vehicle in order to confirm proper operation. Refer to Brake System Vehicle Road Test . Is the condition still present? | Go to Step 2 | System OK |
Brake Fluid Loss
| Step | Action | Yes | No |
| DEFINITION: Brake fluid level is low not related to lining wear. |
| 1 | Were you sent here from the Hydraulic Brake Symptom table? | Go to Step 2 | Go to Symptoms - Hydraulic Brakes |
| 2 | Inspect the following hydraulic brake system components for brake fluid leaks: Flexible brake hose connections; threaded and bolted Flexible brake hose crimp joints Brake pipe fittings Caliper piston seals Wheel cylinder piston seals, if equipped Master cylinder reservoir Master cylinder reservoir low pressure hose, if equipped Brake pressure modulator valve (BPMV) assembly, if equipped Repair or replace components as necessary. Refer to Hydraulic Brake System Diagnosis . Did you find and correct a condition? | Go to Step 8 | Go to Step 3 |
| 3 | Is the vehicle equipped with a vacuum brake booster? | Go to Step 4 | Go to Step 6 |
| 4 | Disconnect the vacuum check valve from the booster to relieve vacuum reserve. Separate the master cylinder from the vacuum brake booster. Do not disconnect any brake pipes. Inspect the rear of the master cylinder for a brake fluid leak. Inspect for brake fluid in the vacuum brake booster. Did you find a brake fluid leak? | Go to Step 5 | Go to Symptoms - Hydraulic Brakes |
| 5 | Replace the brake master cylinder and the vacuum brake booster. Did you complete the replacement? | Go to Step 8 | |
| 6 | Wipe clean the external surface of the master cylinder to hydraulic brake booster area, if equipped. Separate the master cylinder from the hydraulic brake booster, if equipped. Do not disconnect any brake pipes. Inspect the rear of the master cylinder for a brake fluid leak. Did you find a brake fluid leak? | Go to Step 7 | Go to Symptoms - Hydraulic Brakes |
| 7 | Replace the brake master cylinder. Did you complete the replacement? | Go to Step 8 | |
| 8 | Install or connect components that were removed or disconnected during diagnosis. Road test the vehicle to confirm proper operation. Refer to Brake System Vehicle Road Test . Is the condition still present? | Go to Step 2 | System OK |
Brakes Self Apply When Turning Steering Wheel
| Step | Action | Yes | No |
| 1 | Were you sent here from the Hydraulic Brake Symptom table? | Go to Step 2 | Go to Symptoms - Hydraulic Brakes |
| 2 | Inspect the hydraulic brake booster to power steering reservoir return hose for kinks and/or other restrictions. Replace the return hose if restrictions are present. Did you find and correct a condition? | Go to Step 5 | Go to Step 3 |
| 3 | Inspect the brake assist system for proper operation. Refer to Brake Assist System Diagnosis . Did you find and correct a condition? | Go to Step 5 | Go to Step 4 |
| 4 | Inspect the steering system for proper operation. Refer to Symptoms - Power Steering System . Did you find and correct a condition? | Go to Step 5 | Go to Symptoms - Hydraulic Brakes |
| 5 | Road test the vehicle in order to confirm proper operation. Refer to Brake System Vehicle Road Test . Is the condition still present? | Go to Step 2 | System OK |
The numbers below refer to the step numbers on the diagnostic table
- 9: Lubricant leaks from non-brake system components may come in contact with and contaminate brake system components.
- 10: Lubricant leaks from non-brake system components may come in contact with and contaminate brake system components.
- 12: Disc brake rotor shields/backing plates that come in contact with disc brake rotors may cause brake system noise.
- 15: Disc brake rotor thickness variation that exceeds the maximum acceptable level can cause brake pulsation.
- 19: Disc brake rotor thickness variation that exceeds the maximum acceptable level can cause brake pulsation.
- 22: Disc brake rotor assembled lateral runout (LRO) that exceeds the maximum acceptable level can lead to thickness variation.
| Step | Action | Yes | No |
| DEFINITION: This diagnostic table is designed to diagnose ONLY the components of the DISC brake system in order to determine if the DISC brake system is operating properly. You will be directed by the appropriate Symptom table to go to other brake system diagnostic tables as appropriate. |
| 1 | Were you sent here from a Brake Symptom table? | Go to Step 2 | Go to Symptoms - Hydraulic Brakes |
| 2 | Visually inspect the disc brake pads for the following conditions: Refer to Brake Pad Inspection . Lining thickness below specifications Uneven and/or abnormal wear - edge-to-edge and/or side-to-side Looseness or damage - including pad hardware Evidence of contamination from an external substance Did you find any conditions to indicate a concern with any of the front and/or rear disc brake pads? | Go to Step 3 | Go to Step 12 |
| 3 | Are any of the front and/or rear disc brake pads contaminated? | Go to Step 8 | Go to Step 4 |
| 4 | Are any of the front and/or rear disc brake pads worn unevenly? | Go to Step 7 | Go to Step 5 |
| 5 | Are any of the front and/or rear disc brake pads and/or pad hardware loose or damaged? | Go to Step 7 | Go to Step 6 |
| 6 | Remove and inspect the worn disc brake pads for glazing, looseness, heat spots or damage. Replace the worn disc brake pads as a complete axle set. Refer to Front Disc Brake Pads Replacement (1500 Series) or Front Disc Brake Pads Replacement (2500 Series) and/or Rear Disc Brake Pads Replacement (2500 Series) or Rear Disc Brake Pads Replacement (1500 Series) . Did you complete the inspection and replacement? | Go to Step 12 | |
| 7 | CAUTION: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. NOTE: Do NOT disconnect the hydraulic brake flex hoses from the calipers. Remove the front and/or rear disc brake calipers, as appropriate, from the mounting brackets and support the calipers. Refer to Front Brake Caliper Replacement (2500 Series) or Front Brake Caliper Replacement (1500 Series) and/or Rear Brake Caliper Replacement (2500 Series) or Rear Brake Caliper Replacement (1500 Series) . Inspect the disc brake caliper mounting bracket and the mounting/sliding hardware for the following conditions: Refer to Front Disc Brake Mounting and Hardware Inspection and/or Rear Disc Brake Mounting and Hardware Inspection . Binding or seized hardware Worn, damaged or missing hardware components Loose, bent, cracked, or damaged caliper mounting bracket Replace components as required. Refer to the following procedures in Disc Brakes, as required: Front Brake Caliper Bracket Replacement (1500 Series) Front Brake Caliper Bracket Replacement (2500 Series) Rear Brake Caliper Bracket Replacement (1500 Series) Rear Brake Caliper Bracket Replacement (2500 Series) Front Brake Caliper Hardware Replacement (2500 Series) Front Brake Caliper Hardware Replacement (1500 Series) Rear Brake Caliper Hardware Replacement (2500 Series) Rear Brake Caliper Hardware Replacement (1500 Series) Replace the unevenly-worn, loose or damaged disc brake pads as a complete axle set. Refer to Front Disc Brake Pads Replacement (1500 Series) or Front Disc Brake Pads Replacement (2500 Series) and/or Rear Disc Brake Pads Replacement (2500 Series) or Rear Disc Brake Pads Replacement (1500 Series) . Did you complete the inspection and replacement? | Go to Step 12 | |
| 8 | Inspect the disc brake calipers, brake hoses and brake pipes for evidence of an external brake fluid leak. Replace any components found to be leaking brake fluid. Refer to the following procedures as required: Front Brake Caliper Overhaul (2500 Series) or Front Brake Caliper Replacement (2500 Series) Front Brake Caliper Replacement (1500 Series) Rear Brake Caliper Overhaul (2500 Series) or Rear Brake Caliper Replacement (2500 Series) Rear Brake Caliper Replacement (1500 Series) Front Brake Hose Replacement (JH6) Front Brake Hose Replacement (JD9) Rear Brake Hose Replacement (JH6) Rear Brake Hose Replacement (Frame to Rear Axle JH6) Rear Brake Hose Replacement (Frame to Rear Axle JD9) Rear Brake Hose Replacement (JD9) Brake Pipe Replacement Did you find and correct the source of the leak causing contamination of the pads? | Go to Step 11 | Go to Step 9 |
| 9 | Inspect the wheel drive shaft outer seals, if equipped, for damage and evidence of a grease leak. Replace any wheel drive shaft seal that is found to be leaking grease which may be the source of the contamination to the pads. Refer to Wheel Drive Shaft Outer Joint and Boot Replacement , if equipped. Inspect the rear axle seals for damage and evidence of a lubricant leak. Replace any rear axle seal that is found to be leaking lubricant which may be the source of the contamination to the pads. Refer to Rear Axle Shaft Seal and/or Bearing Replacement or Front Wheel Hub, Bearing, and Seal Replacement (2500) or Front Wheel Hub, Bearing, and Seal Replacement (1500) . Did you find and correct the source of the leak causing contamination of the pads? | Go to Step 11 | Go to Step 10 |
| 10 | Inspect the automatic transmission cooling system lines, if equipped, for damage and evidence of an external fluid leak which may be the source of the contamination to the pads. Inspect the power steering system hoses for damage and evidence of an external fluid leak which may be the source of the contamination to the pads. Replace any components found to be leaking fluid which may be the source of the contamination to the pads. Did you find and correct the source of the leak causing contamination of the pads? | Go to Step 11 | |
| 11 | Clean the remaining disc brake system components to remove any traces of the contaminant. CAUTION: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. NOTE: Do NOT disconnect the hydraulic brake flex hoses from the calipers. Remove the front and/or rear disc brake calipers, as appropriate, from the mounting brackets and support the calipers. Refer to Front Brake Caliper Replacement (2500 Series) or Front Brake Caliper Replacement (1500 Series) and/or Rear Brake Caliper Replacement (2500 Series) or Rear Brake Caliper Replacement (1500 Series) . Inspect the disc brake caliper mounting/sliding hardware for the following conditions: Refer to Front Disc Brake Mounting and Hardware Inspection and/or Rear Disc Brake Mounting and Hardware Inspection . Binding or seized hardware Distorted, worn, damaged or missing hardware components Replace the caliper mounting/sliding hardware components as required. Refer to Front Brake Caliper Hardware Replacement (2500 Series) or Front Brake Caliper Hardware Replacement (1500 Series) and/or Rear Brake Caliper Hardware Replacement (2500 Series) or Rear Brake Caliper Hardware Replacement (1500 Series) . Replace the contaminated disc brake pads as a complete axle set. Refer to Front Disc Brake Pads Replacement (1500 Series) or Front Disc Brake Pads Replacement (2500 Series) and/or Rear Disc Brake Pads Replacement (2500 Series) or Rear Disc Brake Pads Replacement (1500 Series) . Did you complete the cleaning, inspection and replacement? | Go to Step 12 | |
| 12 | Visually inspect each of the disc brake rotor shields/backing plates for evidence of contact with the brake rotors. Are any of the brake rotor shields/backing plates contacting the brake rotors? | Go to Step 13 | Go to Step 14 |
| 13 | Repair or replace the disc brake rotor shields/rear brake shield as required. Refer to Front Brake Shield Replacement (1500 Series) or Front Brake Shield Replacement (2500 Series) and/or Rear Brake Shield Replacement . Did you complete the repair or replacement? | Go to Step 14 | |
| 14 | Check the thickness of each of the disc brake rotors. NOTE: Make the following determination AND ANSWER the question INDIVIDUALLY for EACH rotor. Make a determination for each brake rotor if the rotor can be REFINISHED and REMAIN ABOVE the minimum requirements. Refer to Brake Rotor Thickness Measurement .Does the disc brake rotor meet the minimum requirements for REFINISHING? | Go to Step 15 | Go to Step 18 |
| 15 | NOTE: Perform the following inspection AND ANSWER the question INDIVIDUALLY for EACH rotor. Inspect each of the disc brake rotors for thickness variation that exceeds the maximum acceptable level. Refer to Brake Rotor Thickness Variation Measurement .Does the brake rotor exhibit thickness variation that exceeds the maximum acceptable level? | Go to Step 17 | Go to Step 16 |
| 16 | Inspect each of the disc brake rotors for the following surface and wear conditions: Refer to Brake Rotor Surface and Wear Inspection . Heavy rust and/or pitting Cracks and/or heat spots Excessive blueing discoloration Deep or excessive scoring beyond maximum acceptable level NOTE: Make the following determination AND ANSWER the question INDIVIDUALLY for EACH rotor. Make a determination for each brake rotor if the rotor requires refinishing based upon the results of the inspection. If the brake rotor exhibits any of the conditions listed previously, it requires refinishing. Does the brake rotor require REFINISHING? | Go to Step 17 | Go to Step 22 |
| 17 | Refinish the brake rotor. Refer to Brake Rotor Refinishing . Inspect the brake rotor thickness. Refer to Brake Rotor Thickness Measurement . Were you able to REFINISH the brake rotor within the minimum requirements? | Go to Step 22 | Go to Step 21 |
| 18 | Is the brake rotor at or below the DISCARD requirements? | Go to Step 21 | Go to Step 19 |
| 19 | NOTE: Perform the following inspection AND ANSWER the question INDIVIDUALLY for EACH rotor. Inspect each of the disc brake rotors for thickness variation that exceeds the maximum acceptable level. Refer to Brake Rotor Thickness Variation Measurement .Does the brake rotor exhibit thickness variation that exceeds the maximum acceptable level? | Go to Step 21 | Go to Step 20 |
| 20 | Inspect each of the disc brake rotors for the following surface and wear conditions: Refer to Brake Rotor Surface and Wear Inspection . Heavy rust and/or pitting Cracks and/or heat spots Excessive blueing discoloration Deep or excessive scoring beyond maximum acceptable level NOTE: Make the following determination AND ANSWER the question INDIVIDUALLY for EACH rotor. Make a determination for each brake rotor if the rotor requires replacement based upon the results of the inspection. If the brake rotor exhibits any of the conditions listed previously, it requires replacement. Does the brake rotor require REPLACEMENT? | Go to Step 21 | Go to Step 22 |
| 21 | NOTE: Whenever a brake rotor is replaced, the assembled lateral runout (LRO) of the rotor must be measured to ensure optimum performance of the disc brakes. Replace the brake rotor. Refer to Front Brake Rotor Replacement (2500 Series) or Front Brake Rotor Replacement (1500 Series) or Rear Brake Rotor Replacement (1500 Series) or Rear Brake Rotor Replacement (2500 Series) .Did you complete the replacement? | Go to Step 24 | |
| 22 | NOTE: Perform the following inspection AND ANSWER the question INDIVIDUALLY for EACH rotor. Inspect each of the disc brake rotors for assembled LRO that exceeds the maximum acceptable level. Refer to Brake Rotor Assembled Lateral Runout Measurement .Does the brake rotor exhibit assembled LRO that exceeds the maximum acceptable level? | Go to Step 23 | Go to Step 24 |
| 23 | Correct the LRO for each brake rotor that was determined to have LRO exceeding the maximum acceptable level. Refer to Brake Rotor Assembled Lateral Runout Correction . Did you complete the operation? | Go to Step 24 | |
| 24 | Install or connect components that were removed or disconnected during diagnosis. Did you complete the operation? | Disc Brake System OK Return to Symptom Table | |
| CAUTION |
| Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. |
| NOTE |
| Do NOT disconnect the hydraulic brake flex hoses from the calipers. |
| CAUTION |
| Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. |
| NOTE |
| Do NOT disconnect the hydraulic brake flex hoses from the calipers. |
| NOTE |
| Make the following determination AND ANSWER the question INDIVIDUALLY for EACH rotor. |
| NOTE |
| Perform the following inspection AND ANSWER the question INDIVIDUALLY for EACH rotor. |
| NOTE |
| Make the following determination AND ANSWER the question INDIVIDUALLY for EACH rotor. |
| NOTE |
| Perform the following inspection AND ANSWER the question INDIVIDUALLY for EACH rotor. |
| NOTE |
| Make the following determination AND ANSWER the question INDIVIDUALLY for EACH rotor. |
| NOTE |
| Whenever a brake rotor is replaced, the assembled lateral runout (LRO) of the rotor must be measured to ensure optimum performance of the disc brakes. |
| NOTE |
| Perform the following inspection AND ANSWER the question INDIVIDUALLY for EACH rotor. |
| Step | Action | Yes | No |
| DEFINITION: This diagnostic table is designed to diagnose ONLY the components of the HYDRAULIC brake system in order to determine if the HYDRAULIC brake system is operating properly. You will be directed by the appropriate Symptom table to go to other brake system diagnostic tables as appropriate. |
| 1 | Were you sent here from a Brake Symptom table? | Go to Step 2 | Go to Symptoms - Hydraulic Brakes |
| 2 | Inspect and adjust the brake fluid level in the brake master cylinder. Refer to Master Cylinder Reservoir Filling . Was the brake fluid level low? | Go to Step 3 | Go to Step 4 |
| 3 | Inspect the brake fluid for the following conditions, indicating brake fluid contamination: Fluid separation, indicating two types of fluid are present Swirled appearance - oil-based substance Layered appearance - silicone-based substance Fluid discoloration Cloudy appearance - moisture Dark appearance/suspended particles in fluid - dirt, rust, corrosion, brake dust Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for swelling, indicating fluid contamination. Do any of the above conditions exist? | Go to Step 5 | Go to Step 6 |
| 4 | Inspect the brake fluid for the following conditions, indicating brake fluid contamination: Fluid separation, indicating two types of fluid are present Swirled appearance - oil-based substance Layered appearance - silicone-based substance Fluid discoloration Cloudy appearance - moisture Dark appearance/suspended particles in fluid - dirt, rust, corrosion, brake dust Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for swelling, indicating fluid contamination. Do any of the above conditions exist? | Go to Step 5 | Go to Step 12 |
| 5 | Flush the hydraulic brake system. Refer to Hydraulic Brake System Flushing . If the brake fluid WAS contaminated with an oil-based or a silicone-based fluid, indicated by fluid separation and/or a swollen master cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform the following steps. Refer to the procedures indicated. Remove ALL of the following components listed. Each component contains internal rubber seals/linings which have been contaminated. Clean out the hydraulic brake pipes using denatured alcohol, or equivalent. Dry the brake pipes using non-lubricated, filtered air. Repair or replace ALL of the following components listed. Each component contains internal rubber seals/linings which have been contaminated. Master Cylinder Replacement (JD9) Master Cylinder Replacement (JH6) Master Cylinder Replacement (Two-mode Hybrid) Brake master cylinder reservoir: Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the reservoir using non-lubricated, filtered air, or if necessary, replace the brake master cylinder reservoir. Replace the brake master cylinder reservoir cap diaphragm. Front Brake Hose Replacement (JH6) Front Brake Hose Replacement (JD9) Rear Brake Hose Replacement (JH6) Rear Brake Hose Replacement (Frame to Rear Axle JH6) Rear Brake Hose Replacement (Frame to Rear Axle JD9) Rear Brake Hose Replacement (JD9) Front Brake Caliper Overhaul (2500 Series) or Front Brake Caliper Replacement (2500 Series) Front Brake Caliper Replacement (1500 Series) Rear Brake Caliper Overhaul (2500 Series) or Rear Brake Caliper Replacement (2500 Series) Rear Brake Caliper Replacement (1500 Series) Brake Pressure Modulator Valve Replacement Non-Hybrid Less than 3900 kg (8600 lb) GVW or Brake Pressure Modulator Valve Replacement Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW If the brake fluid was NOT contaminated with an oil-based fluid, but WAS contaminated with water or dirt, rust, corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm which may have allowed moisture or dirt to enter the system. Refill and bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System Bleeding (Pressure) . Did you complete the operation and any required repairs and/or replacements? | Go to Step 9 | |
| 6 | Inspect the following hydraulic brake system components for external fluid leaks Repair or replace any of the components found to be leaking brake fluid. Refer to the appropriate procedures: Master Cylinder Replacement (JD9) Master Cylinder Replacement (JH6) Master Cylinder Replacement (Two-mode Hybrid) Brake master cylinder reservoir cap diaphragm Front Brake Hose Replacement (JH6) Front Brake Hose Replacement (JD9) Rear Brake Hose Replacement (JH6) Rear Brake Hose Replacement (Frame to Rear Axle JH6) Rear Brake Hose Replacement (Frame to Rear Axle JD9) Rear Brake Hose Replacement (JD9) Brake Pipe Replacement Front Brake Caliper Overhaul (2500 Series) or Front Brake Caliper Replacement (2500 Series) Front Brake Caliper Replacement (1500 Series) Rear Brake Caliper Overhaul (2500 Series) or Rear Brake Caliper Replacement (2500 Series) Rear Brake Caliper Replacement (1500 Series) Brake Pressure Modulator Valve Replacement Non-Hybrid Less than 3900 kg (8600 lb) GVW or Brake Pressure Modulator Valve Replacement Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW If you repaired or replaced any of the brake system components listed, bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System Bleeding (Pressure) . While bleeding the hydraulic brake system, observe for the following conditions: The presence of air in the system at a bleeder valve location other than at the repair location, except if the brake master cylinder was replaced An unrestricted and even flow of brake fluid per axle during the bleeding procedure Did you find and correct a condition? | Go to Step 7 | Go to Step 12 |
| 7 | Was there air in the system at a bleeder valve location other than at the repair location, except if the brake master cylinder was replaced? | Go to Step 19 | Go to Step 8 |
| 8 | Was the flow of brake fluid unrestricted and even per axle during the bleeding procedure? | Go to Step 9 | Go to Step 10 |
| 9 | Inspect the hydraulic function of the brake calipers for proper operation. Refer to Hydraulic Brake Component Operation Visual Inspection . Was the hydraulic function of the brake calipers operating properly? | Go to Step 21 | Go to Step 14 |
| 10 | Was the flow of brake fluid restricted or uneven through front axle hydraulic components during the bleeding procedure? | Go to Step 13 | Go to Step 11 |
| 11 | Was the flow of brake fluid restricted or uneven through rear axle hydraulic components during the bleeding procedure? | Go to Step 17 | |
| 12 | Inspect the hydraulic function of the brake calipers for proper operation. Refer to Hydraulic Brake Component Operation Visual Inspection . Was the hydraulic function of the brake calipers operating properly? | Go to Step 15 | Go to Step 13 |
| 13 | Determine if the brake caliper is restricting the flow of brake fluid and/or not operating properly: Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation . Open the suspected caliper bleeder valve. Using a large C-clamp, compress the caliper piston and observe for an unrestricted flow of brake fluid and for free movement of the caliper piston. Close the caliper bleeder valve. Was the flow of brake fluid unrestricted and did the caliper piston move freely? | Go to Step 17 | Go to Step 14 |
| 14 | Repair or replace any brake caliper that was not operating properly. Refer to the appropriate procedure: Front Brake Caliper Overhaul (2500 Series) or Front Brake Caliper Replacement (2500 Series) or Front Brake Caliper Replacement (1500 Series) Rear Brake Caliper Overhaul (2500 Series) or Rear Brake Caliper Replacement (2500 Series) or Rear Brake Caliper Replacement (1500 Series) Did you complete the repair and/or replacement? | Go to Step 21 | |
| 15 | Bleed the hydraulic brake system to observe for the presence of air in the system and to observe for an unrestricted and even flow of brake fluid per axle during the bleeding procedure. Refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System Bleeding (Pressure) . Was there air in the system? | Go to Step 19 | Go to Step 16 |
| 16 | Was the flow of brake fluid unrestricted and even per axle during the bleeding procedure? | Go to Step 21 | Go to Step 17 |
| 17 | Inspect the hydraulic brake pipes and flexible brake hoses for signs of a fluid restriction; such as being bent, kinked, pinched or damaged. Refer to Brake Pipe and Hose Inspection . Replace any of the hydraulic brake pipes and/or flexible brake hoses found to be bent, kinked, pinched, or damaged. Refer to the following procedures as necessary: Front Brake Hose Replacement (JH6) Front Brake Hose Replacement (JD9) Rear Brake Hose Replacement (JH6) Rear Brake Hose Replacement (Frame to Rear Axle JH6) Rear Brake Hose Replacement (Frame to Rear Axle JD9) Rear Brake Hose Replacement (JD9) Brake Pipe Replacement If none of the hydraulic brake pipes or flexible brake hoses were visibly bent, kinked, pinched, or damaged, replace the hydraulic brake flex hose at the restricted location. Did you find and correct a condition? | Go to Step 21 | Go to Step 18 |
| 18 | Replace the brake pressure modulator valve (BPMV), in order to correct the hydraulic brake dynamic rear proportioning mechanical operation. Refer to Brake Pressure Modulator Valve Replacement Non-Hybrid Less than 3900 kg (8600 lb) GVW or Brake Pressure Modulator Valve Replacement Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW. Did you complete the replacement? | Go to Step 21 | |
| 19 | Inspect the hydraulic brake system components for brake fluid seepage at a seal and/or fitting location, which may have drawn air into the system. Inspect the hydraulic brake system components for evidence of a recent repair, which may have introduced air into the system. Repair or replace any of the components found to be installed incorrectly or seeping brake fluid. Did you find and correct a condition? | Go to Step 21 | Go to Step 20 |
| 20 | Inspect the brake master cylinder for internal fluid leaks. Refer to Brake System Internal Leak Test (Two-mode Hybrid) or Brake System Internal Leak Test (Non-Hybrid) . Repair or replace the brake master cylinder if it is found to be leaking brake fluid internally. Refer to Master Cylinder Replacement (JD9) or Master Cylinder Replacement (JH6) or Master Cylinder Replacement (Two-mode Hybrid) . Did you find and correct a condition? | Go to Step 21 | Return to Symptom Table |
| 21 | Install or connect components that were removed or disconnected during diagnosis. Did you complete the operation? | Hydraulic Brake System OK Return to Symptom Table | |
Brake Hydraulic and Assist System Diagnosis (Two-mode Hybrid)
| Step | Action | Yes | No |
| DEFINITION: This diagnostic table is designed to diagnose ONLY the components of the brake HYDRAULIC and ASSIST systems in order to determine if the HYDRAULIC and ASSIST systems are operating properly. You will be directed by the appropriate Symptom table to go to other brake system diagnostic tables as appropriate. |
| 1 | Were you sent here from a Brake Symptom table or from an electrical diagnostic procedure? | Go to Step 2 | Go to Symptoms - Hydraulic Brakes |
| 2 | Inspect the brake fluid for the following conditions, indicating brake fluid contamination: Fluid separation, indicating two types of fluid are present Swirled appearance - oil-based substance Layered appearance - silicone-based substance Fluid discoloration Cloudy appearance - moisture Dark appearance/suspended particles in fluid - dirt, rust, corrosion, brake dust Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for swelling, indicating fluid contamination. Do any of the above fluid contamination conditions exist? | Go to Step 3 | Go to Step 4 |
| 3 | Flush the hydraulic brake system and repair or replace components as directed based upon the type of fluid contamination present. Refer to Hydraulic Brake System Flushing . Pressure bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System Bleeding (Pressure) . Perform the Antilock Brake System Automated Bleed . Did you complete the operation and any required repairs and/or replacements? | Go to Step 4 | |
| 4 | Inspect the following hydraulic brake system components for external fluid leaks: Hydraulic brake hoses Hydraulic brake pipes Brake master cylinder reservoir to brake pressure modulator valve (BPMV) feed and return hoses Brake calipers Brake master cylinder BPMV Inspect the hydraulic brake pipes, master cylinder reservoir hoses, and flexible brake hoses for signs of a fluid restriction, such as being bent, kinked, pinched, or damaged. Refer to Brake Pipe and Hose Inspection . Repair or replace any of the hydraulic components found to be leaking brake fluid. Replace any of the hydraulic brake pipes, master cylinder reservoir hoses, and/or flexible brake hoses found to be bent, kinked, pinched, or damaged. Refer to the appropriate procedures: Master Cylinder Replacement (JD9) Master Cylinder Replacement (JH6) Master Cylinder Replacement (Two-mode Hybrid) Brake master cylinder reservoir cap diaphragm Front Brake Hose Replacement (JH6) Front Brake Hose Replacement (JD9) Rear Brake Hose Replacement (JH6) Rear Brake Hose Replacement (Frame to Rear Axle JH6) Rear Brake Hose Replacement (Frame to Rear Axle JD9) Rear Brake Hose Replacement (JD9) Brake Pipe Replacement Brake Master Cylinder Reservoir Hose Replacement Front Brake Caliper Overhaul (2500 Series) or Front Brake Caliper Replacement (2500 Series) Front Brake Caliper Replacement (1500 Series) Rear Brake Caliper Overhaul (2500 Series) or Rear Brake Caliper Replacement (2500 Series) Rear Brake Caliper Replacement (1500 Series) Brake Pressure Modulator Valve Replacement Did you complete the inspections and any necessary repairs or replacements? | Go to Step 5 | |
| 5 | Perform the system deactivation and vehicle preparation steps: NOTE: To ensure the complete brake modulator and high pressure accumulator (HPA) pressure relief procedure is allowed to occur; the brake controller must see 1 pedal apply with the engine running, followed by a proper shutdown without applying the brake pedal. Start the engine and allow to idle. Apply and release the brake pedal. Place the transmission in PARK. NOTE: The ignition must be OFF, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1-3 minutes. Turn the ignition OFF, without pausing at ACCESSORY, and without applying the brake pedal. Remove the ignition key. Wait approximately 1-3 minutes until the brake modulator and HPA pressure relief is complete. Inspect and adjust the brake fluid level in the brake master cylinder reservoir. Refer to Master Cylinder Reservoir Filling . Connect a battery charger to the 12V battery. Refer to Battery Charging . Install a scan tool to the vehicle. NOTE: The ignition must remain ON, engine OFF during the remainder of this diagnostic procedure, unless otherwise instructed. Turn the ignition ON, engine OFF. Ensure the scan tool is communicating with the vehicle. Did you complete the system deactivation and vehicle preparation steps? | Go to Step 6 | |
| 6 | Have you already performed the brake sensor performance data checks as part of an electrical DTC diagnostic procedure? | Go to Step 8 | Go to Step 7 |
| 7 | Perform the brake sensor performance data check procedure. Start the engine and allow it to idle. Place the transmission in PARK. NOTE: Do not depress the brake pedal during the EBCM relearn. Using the scan tool, perform the EBCM relearn. Do not depress the brake pedal. Select Diagnostics. Select the appropriate vehicle information. Select Chassis. Select EBCM. Select Module Setup. Select EBCM Relearn and follow the scan tool instructions. NOTE: To ensure the complete brake modulator and high pressure accumulator (HPA) pressure relief procedure is allowed to occur; the brake controller must see 1 pedal apply with the engine running, followed by a proper shutdown without applying the brake pedal. Allow the engine to run at idle. Apply and release the brake pedal. NOTE: The ignition must be OFF, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1-3 minutes. Turn the ignition OFF, without pausing at ACCESSORY, and without applying the brake pedal. Remove the ignition key. Wait approximately 3 minutes to ensure the brake modulator and HPA pressure relief is complete. NOTE: The ignition must remain ON, engine OFF during this entire procedure. Turn the ignition ON, engine OFF, and do not apply the brake pedal. Using the scan tool, select Data Display for the EBCM, scroll through the data list, select and accept the following: Master Cylinder Pressure Sensor Rear Brake Pressure Sensor Brake Pressure Sensor Accumulator Pressure Sensor Brake Master Cylinder (BMC) Primary Piston Position Sensor 5V reference BMC Primary Piston Sensor A BMC Primary Piston Sensor B Ignition ON, engine OFF, brakes not applied, verify the following sensor parameters are within the specified values: Master Cylinder Pressure Sensor - Less than 100 kPa (15 psi) Rear Brake Pressure Sensor - Less than 100 kPa (15 psi) Brake Pressure Sensor - Less than 100 kPa (15 psi) Accumulator Pressure Sensor - Less than 800 kPa (116 psi) If any of the sensor parameters on the scan tool are not within the specified ranges, replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement . With the ignition ON, engine OFF, brakes not applied, verify the following sensor parameters are within the specified values: BMC Primary Piston Position Sensor 5V Reference - Between 4.75V and 5.25V BMC Primary Piston Position Sensor A - Less than 0.8V BMC Primary Piston Position Sensor B - Greater than 4.2V If any of the sensor parameters are not within the specified ranges, see DTC C0277 for further diagnostic information. Did you complete the operation and any required repairs and/or replacements? | Go to Step 8 | |
| 8 | Inspect for proper brake pedal travel. Refer to Brake Pedal Travel Measurement and Inspection (Non-Hybrid) or Brake Pedal Travel Measurement and Inspection (Two-mode Hybrid) . Was the brake pedal travel within specification? | Go to Step 10 | Go to Step 9 |
| 9 | Inspect for worn, missing, misaligned, bent or damaged brake pedal system components. For the brake pedal pushrod component inspection, refer to Brake Pedal Pushrod Inspection . Inspect the brake pedal bushings for excessive wear and/or damage and inspect the brake pedal for a misaligned, bent and/or damaged condition. Replace the brake pedal system components that are worn, missing, misaligned, bent or damaged. Perform the entire Antilock Brake System Automated Bleed . Re-inspect for proper brake pedal travel. Refer to Brake Pedal Travel Measurement and Inspection (Non-Hybrid) or Brake Pedal Travel Measurement and Inspection (Two-mode Hybrid) . Is the brake pedal now within specification? | Go to Step 10 | Go to Step 20 |
| 10 | Perform the brake master cylinder (BMC) primary circuit test: NOTE: The ignition must remain ON, engine OFF during this entire procedure. Ensure the ignition is ON, engine OFF. Using the scan tool, select Data Display for the EBCM, scroll through the Data list, select and accept the following: Master Cylinder Pressure Sensor Brake Master Cylinder (BMC) Primary Piston Reference Position While observing the master cylinder pressure and the BMC primary piston position sensors on the scan tool data display, using moderate speed and moderate effort, apply and maintain the brake pedal to a force of 2500 kPa (363 psi). Wait for 10 seconds for the system to settle. While ensuring 2500 kPa (363 psi) of force is maintained, observe pedal operation for an additional 30 seconds. NOTE: The brake pedal should remain firm and steady while maintaining the apply force during the observation period. Did the brake pedal remain firm and steady during the observation period? | Go to Step 11 | Go to Step 20 |
| 11 | Ensure the brake corners are functioning properly: NOTE: The aid of an assistant will be necessary. Raise and support the vehicle. Allow the tire and wheel assemblies to rotate freely. Refer to Lifting and Jacking the Vehicle . NOTE: The ignition must remain ON, engine OFF during this entire procedure. Ensure the ignition is ON, engine OFF. Verify the park brake is released. Place the transmission in NEUTRAL. Continue observing the master cylinder pressure sensor on the scan tool data display. Using moderate speed and moderate effort, apply and maintain the brake pedal to a force of 2500-3000 kPa (363-435 psi). While maintaining the brake apply force, wait 10 seconds, then have an assistant attempt to rotate the rear wheels. If the rear wheels are locked, maintain that amount of apply force. If the rear wheels are not locked, increase the apply force just enough to lock the rear wheels. Maintain that amount of apply force. Have an assistant attempt to rotate the front wheels. Inspect any suspect brake corners for possible component hydraulic restriction and/or mechanical binding. Release the brake pedal and have an assistant rotate each of the wheels again to check for possible brake drag. NOTE: None of the wheels should be able to be rotated during the brake apply. None of the wheels should exhibit drag after brake release. Did the brake corners apply and release properly? | Go to Step 14 | Go to Step 12 |
| 12 | Determine if the brake caliper is restricting the flow of brake fluid and/or not operating properly. Remove the appropriate tire and wheel assembly. Refer to Tire and Wheel Removal and Installation . Inspect the hydraulic function of the brake caliper for proper operation. Refer to Hydraulic Brake Component Operation Visual Inspection . Open the suspected caliper bleeder valve. Using a large C-clamp or clamps, evenly compress the caliper piston or pistons. Observe for an unrestricted flow of brake fluid and for free movement of the caliper piston or pistons. Close the caliper bleeder valve. Was the flow of brake fluid unrestricted and did the caliper piston or pistons move freely? | Go to Step 13 | Go to Step 19 |
| 13 | Determine if the brake hose is restricting the flow of brake fluid. Carefully inspect the flexible brake hose at the restricted location for signs of a fluid restriction, such as being bent, kinked, pinched, or damaged. Refer to Brake Pipe and Hose Inspection . Replace the brake hose if it is found to be damaged. Refer to the appropriate procedure: Front Brake Hose Replacement (JH6) Front Brake Hose Replacement (JD9) Rear Brake Hose Replacement (JH6) Rear Brake Hose Replacement (Frame to Rear Axle JH6) Rear Brake Hose Replacement (Frame to Rear Axle JD9) Rear Brake Hose Replacement (JD9) Did you complete the inspection and any necessary replacement? | Go to Step 14 | |
| 14 | Perform the BMC secondary circuit test. NOTE: The aid of an assistant will be necessary. Reinstall the tire and wheel assembly, if removed previously to verify brake corner function. With the vehicle still supported at a working height, allow the tire and wheel assemblies to rotate freely. NOTE: The ignition must remain ON, engine OFF during this entire procedure. Ensure the switch is ON, engine OFF and the transmission is in NEUTRAL. Continue observing the master cylinder pressure sensor on the scan tool data display. Using moderate speed and moderate effort, apply and maintain the brake pedal to a force of 2500-3000 kPa (363-435 psi). While maintaining the brake pedal apply force, wait 10 seconds, then have an assistant attempt to rotate the rear wheels. If the rear wheels are locked, maintain that amount of apply force. If the rear wheels are not locked, increase the apply force just enough to lock the rear wheels. Maintain that amount of apply force. Wait 20 seconds, then attempt to rotate the front wheels. Attempt to rotate the rear wheels again. NOTE: None of the wheels should be able to be rotated during the brake apply. Could any of the wheels be rotated during the brake apply? | Go to Step 15 | Go to Step 18 |
| 15 | Were either of the front wheels able to be rotated during the brake apply? | Go to Step 20 | Go to Step 16 |
| 16 | Perform the brake modulator motor, HPA, and fluid control solenoid test: Using the scan tool data display, scroll through the Data List, select and accept Accumulator Pressure Sensor. While observing the accumulator pressure sensor data, start the engine and allow it to idle to activate and pressurize the brake system. Observe the accumulator pressure sensor data for 40 seconds. NOTE: The accumulator pressure sensor data should rise from 0 kPa (0 psi) to 17,000 kPa (2466 psi) within 40 seconds. Did the brake modulator provide the specified amount of pressure within the allotted time period? | Go to Step 18 | Go to Step 17 |
| 17 | Perform the entire brake system automated bleed procedure. Refer to Antilock Brake System Automated Bleed . Place the transmission in PARK. NOTE: The ignition must be OFF, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1-3 minutes. Turn the ignition OFF, without pausing at ACCESSORY, and without applying the brake pedal. Remove the ignition key. Wait approximately 1-3 minutes until the brake modulator and HPA pressure relief is complete. Again perform the brake modulator motor, HPA, and fluid control solenoid test: Using the scan tool data display, scroll through the Data List, select and accept Accumulator Pressure Sensor. While observing the accumulator pressure sensor data, start the engine and allow it to idle to activate and pressurize the brake system. Observe the accumulator pressure sensor data for 40 seconds. NOTE: The accumulator pressure sensor should rise from 0 kPa (0 psi) to 17,000 kPa (2466 psi) within 40 seconds. Did the brake modulator provide the specified amount of pressure within the allotted time period? | Go to Step 18 | Go to Step 21 |
| 18 | Perform the brake pedal simulator test: Start the engine and allow to idle to activate and pressurize the brake system. Continue observing the master cylinder pressure and the BMC primary piston position sensors on the scan tool data display. Using moderate speed and moderate effort, apply and maintain the brake pedal to a force of 2500 kPa (363 psi). Observe both pedal operation and master cylinder pressure for a period of 20 seconds. NOTE: The brake pedal should remain firm and steady and master cylinder pressure should remain constant. Did the brake pedal remain firm and steady, and did the master cylinder pressure remain constant? | Go to Step 22 | Go to Step 21 |
| 19 | Repair or replace any brake caliper that was not operating properly. Refer to the appropriate procedure: Front Brake Caliper Replacement (2500 Series) or Front Brake Caliper Replacement (1500 Series) or Front Brake Caliper Overhaul (2500 Series) Rear Brake Caliper Replacement (2500 Series) or Rear Brake Caliper Replacement (1500 Series) or Rear Brake Caliper Overhaul (2500 Series) Did the brake pedal remain firm and steady, and did the master cylinder pressure remain constant? | Go to Step 22 | |
| 20 | Replace the brake master cylinder. Refer to Master Cylinder Replacement (JD9) or Master Cylinder Replacement (JH6) or Master Cylinder Replacement (Two-mode Hybrid) . Pressure bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System Bleeding (Pressure) . Perform the entire brake system automated bleed procedure. Refer to Antilock Brake System Automated Bleed . Did you complete the replacement and repair procedures? | Go to Step 22 | |
| 21 | Replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement . Pressure bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System Bleeding (Pressure) . Perform the entire brake system automated bleed procedure. Refer to Antilock Brake System Automated Bleed . | Go to Step 22 | |
| 22 | Install or connect any components that were removed or disconnected during diagnosis. Did you complete the operation? | Brake Hydraulic and Assist System OK Return to Symptom Table | |
| NOTE |
| To ensure the complete brake modulator and high pressure accumulator (HPA) pressure relief procedure is allowed to occur; the brake controller must see 1 pedal apply with the engine running, followed by a proper shutdown without applying the brake pedal. |
| NOTE |
| The ignition must be OFF, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1-3 minutes. |
| NOTE |
| The ignition must remain ON, engine OFF during the remainder of this diagnostic procedure, unless otherwise instructed. |
| NOTE |
| Do not depress the brake pedal during the EBCM relearn. |
| NOTE |
| To ensure the complete brake modulator and high pressure accumulator (HPA) pressure relief procedure is allowed to occur; the brake controller must see 1 pedal apply with the engine running, followed by a proper shutdown without applying the brake pedal. |
| NOTE |
| The ignition must be OFF, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1-3 minutes. |
| NOTE |
| The ignition must remain ON, engine OFF during this entire procedure. |
| NOTE |
| The ignition must remain ON, engine OFF during this entire procedure. |
| NOTE |
| The brake pedal should remain firm and steady while maintaining the apply force during the observation period. |
| NOTE |
| The aid of an assistant will be necessary. |
| NOTE |
| The ignition must remain ON, engine OFF during this entire procedure. |
| NOTE |
| None of the wheels should be able to be rotated during the brake apply. None of the wheels should exhibit drag after brake release. |
| NOTE |
| The aid of an assistant will be necessary. |
| NOTE |
| The ignition must remain ON, engine OFF during this entire procedure. |
| NOTE |
| None of the wheels should be able to be rotated during the brake apply. |
| NOTE |
| The accumulator pressure sensor data should rise from 0 kPa (0 psi) to 17,000 kPa (2466 psi) within 40 seconds. |
| NOTE |
| The ignition must be OFF, without pausing at ACCESSORY, and without applying the brake pedal to ensure the brake modulator and high pressure accumulator (HPA) pressure relief occurs. This process will take approximately 1-3 minutes. |
| NOTE |
| The accumulator pressure sensor should rise from 0 kPa (0 psi) to 17,000 kPa (2466 psi) within 40 seconds. |
| NOTE |
| The brake pedal should remain firm and steady and master cylinder pressure should remain constant. |
Brake Assist System Diagnosis
| Step | Action | Yes | No |
| DEFINITION: This diagnostic table is designed to diagnose ONLY the components of the brake ASSIST system in order to determine if the brake ASSIST system is operating properly. You will be directed by the appropriate Symptom table to go to other brake system diagnostic tables as appropriate. |
| 1 | Were you sent here from a Brake Symptom table? | Go to Step 3 | Go to Step 2 |
| 2 | Were you sent here directly from an electrical diagnostic to investigate vacuum as a possible concern? | Go to Step 5 | Go to Symptoms - Hydraulic Brakes |
| 3 | Inspect for proper brake pedal travel. Refer to Brake Pedal Travel Measurement and Inspection (Non-Hybrid) or Brake Pedal Travel Measurement and Inspection (Two-mode Hybrid) . Is the brake pedal travel distance within the acceptable limits? | Go to Step 5 | Go to Step 4 |
| 4 | Inspect for worn, missing, misaligned, bent or damaged brake pedal system components. For the brake pedal pushrod component inspection, refer to Brake Pedal Pushrod Inspection . Inspect the brake pedal bushings for excessive wear and/or damage and inspect the brake pedal for a misaligned, bent and/or damaged condition. Replace the brake pedal system components that are worn, missing, misaligned, bent or damaged. Did you find and replace any worn, missing, misaligned, bent or damaged brake pedal system components? | Go to Step 5 | Go to Hydraulic Brake System Diagnosis to check for internal and external fluid leaks and air in the hydraulic brake system |
| 5 | Check the engine vacuum source that supplies vacuum to the vacuum brake booster. Refer to Brake System Vacuum Source Test . Is the vacuum reading within the acceptable limits? | Go to Step 6 | Go to Engine Controls Diagnostics Information to check for vacuum issues, including vacuum pump operation, if equipped |
| 6 | Does the condition occur during cold start-up conditions? | Go to Step 7 | Go to Step 8 |
| 7 | Check engine vacuum, and vacuum pump operation, if equipped, under the same cold start-up conditions. Refer to Engine Controls Diagnostics. Did you find and correct a condition? | Go to Step 22 | Go to Step 9 |
| 8 | During the vacuum source test, did the vacuum booster check valve operate properly? | Go to Step 10 | Go to Step 9 |
| 9 | Replace the vacuum booster check valve. Refer to Power Brake Booster Vacuum Check Valve and Hose Replacement . Did you complete the replacement? | Go to Step 10 | |
| 10 | If equipped with a booster mounted separate vacuum sensor, inspect the vacuum sensor grommet for cracks, cuts, dry-rot, or damage. Does the vacuum sensor grommet exhibit any of the conditions listed? | Go to Step 11 | Go to Step 12 |
| 11 | Replace the vacuum sensor grommet. Did you complete the replacement? | Go to Step 12 | |
| 12 | If the vehicle is equipped with a vacuum sensor, install a scan tool. Using the Data Display function, determine if brake booster vacuum sensor data is available within either the chassis brake controls area or the powertrain engine controls area. Is vacuum sensor data available through the scan tool? | Go to Step 13 | Go to Step 16 |
| 13 | Perform the vacuum booster leak-down test using a scan tool: Release the brake pedal. Accelerate the engine to approximately 3000 RPM, then release the throttle. Wait 2-3 seconds and repeat once. Turn the ignition OFF. Turn the ignition ON. Do not start the engine. Observe and record the vacuum sensor reading on the scan tool over a period of 60 seconds. IMPORTANT: Vacuum readings will decrease by approximately 2.7 kPa (0.8 Hg) for every 305 m (1000 ft) of elevation above sea level. Determine the rate of vacuum leak. Specification: Maximum allowable vacuum leak rate: 10 kPa (3 in Hg) in 60 seconds Was the rate of vacuum leak within the specified allowable range? | Go to Step 18 | Go to Step 14 |
| 14 | Deplete the vacuum reserve by pressing the brake pedal several times, or by removing the vacuum booster check valve. Separate the master cylinder from the vacuum brake booster. Do not disconnect any brake pipes. Refer to Master Cylinder Replacement (JD9) or Master Cylinder Replacement (JH6) or Master Cylinder Replacement (Two-mode Hybrid) . If equipped with a vacuum seal on the rear of the master cylinder, inspect the seal for damage and correct positioning on the master cylinder. Replace the vacuum seal as necessary. Carefully reinstall the master cylinder to the brake booster. Refer to Master Cylinder Replacement (JD9) or Master Cylinder Replacement (JH6) or Master Cylinder Replacement (Two-mode Hybrid) . Did you complete the operation? | Go to Step 15 | |
| 15 | Perform the vacuum booster leak-down test using a scan tool: Release the brake pedal. Accelerate the engine to approximately 3000 RPM, then release the throttle. Wait 2-3 seconds and repeat once. Turn the ignition OFF. Turn the ignition ON. Do not start the engine. Observe and record the vacuum sensor reading on the scan tool over a period of 60 seconds. IMPORTANT: Vacuum readings will decrease by approximately 2.7 kPa (0.8 Hg) for every 305 m (1000 ft) of elevation above sea level. Determine the rate of vacuum leak. Specification: Maximum allowable vacuum leak rate: 10 kPa (3 in Hg) in 60 seconds Was the rate of vacuum leak within the specified allowable range? | Go to Step 22 | Go to Step 21 |
| 16 | Separate the master cylinder from the vacuum brake booster. Do not disconnect any brake pipes. Before removing the master cylinder, first deplete the vacuum by removing the check valve or applying the brake pedal several times. Refer to Master Cylinder Replacement (JD9) or Master Cylinder Replacement (JH6) or Master Cylinder Replacement (Two-mode Hybrid) . If equipped with a vacuum seal on the rear of the master cylinder, inspect the seal for damage and correct positioning on the master cylinder. If equipped with a vacuum seal that is part of the booster, inspect the seal for damage. Does the vacuum seal exhibit any of the conditions listed? | Go to Step 17 | Go to Step 18 |
| 17 | If equipped with a vacuum seal on the rear of the master cylinder, replace the vacuum seal as necessary. Ensure the seal is positioned correctly during installation. If equipped with a vacuum seal that requires replacement and which is part of the booster, the booster assembly must be replaced. Carefully reinstall the master cylinder to the brake booster. Refer to Master Cylinder Replacement (JD9) or Master Cylinder Replacement (JH6) or Master Cylinder Replacement (Two-mode Hybrid) . Did you complete the replacement? | Go to Step 18 | |
| 18 | Perform the vacuum boost functional test: If still separated, reinstall the master cylinder to the booster. Refer to Master Cylinder Replacement (JD9) or Master Cylinder Replacement (JH6) or Master Cylinder Replacement (Two-mode Hybrid) . If the engine was started after reinstalling the master cylinder to the booster, perform the following: With the engine OFF, depress the brake pedal several times to deplete the vacuum reserve. Depress and maintain moderate foot pressure on the brake pedal. Start the engine and observe pedal operation. Observe for audible vacuum leaks. The brake pedal should fall slightly, then hold. Is there an audible vacuum leak coming from the brake pedal area? | Go to Step 21 | Go to Step 19 |
| 19 | Did the brake pedal fall slightly after the engine was started, then hold? | Go to Step 20 | Go to Step 21 |
| 20 | Perform the vacuum booster leak-down test: Release the brake pedal. Accelerate the engine to approximately 3000 RPM, then release the throttle. Wait 2-3 seconds and repeat once. Turn the ignition OFF. Wait 60 seconds. Depress the brake pedal 2 times to check for vacuum booster available vacuum reserve. Observe pedal effort. Both pedal applies should be assisted The amount of assist could diminish slightly with the second apply Were both pedal applies power assisted? | Go to Step 22 | Go to Step 21 |
| 21 | Replace the vacuum brake booster. Refer to Power Vacuum Brake Booster Replacement . Did you complete the replacement? | Go to Step 22 | |
| 22 | Install or connect any components that were removed or disconnected during diagnosis. Did you complete the operation? | Brake Assist System OK Return to Symptom Table | |
| IMPORTANT |
| Vacuum readings will decrease by approximately 2.7 kPa (0.8 Hg) for every 305 m (1000 ft) of elevation above sea level. |
| IMPORTANT |
| Vacuum readings will decrease by approximately 2.7 kPa (0.8 Hg) for every 305 m (1000 ft) of elevation above sea level. |
Preliminary Inspections
- Visually inspect easily accessible brake system components for obvious damage and/or leaks which may indicate that the vehicle should not be driven until further inspections have been completed.
- Inspect the brake master cylinder reservoir fluid level and adjust only if necessary for brake system road testing. Refer to «Master Cylinder Reservoir Filling»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system__master-cylinder-reservoir-filling) .
- Inspect the tire inflation pressures and adjust as necessary.
- Inspect the tire tread patterns to ensure that they are the same or very similar, especially per axle.
- Ensure that the vehicle is not loaded unevenly prior to brake system road testing.
Road Testing Procedure
| WARNING | Road test a vehicle under safe conditions and while obeying all traffic laws. Do not attempt any maneuvers that could jeopardize vehicle control. Failure to adhere to these precautions could lead to serious personal injury and vehicle damage. |
- Start the engine and allow it to idle.
- Check to see if the brake system warning lamp remains illuminated.
- If the brake system warning lamp remains illuminated, DO NOT proceed to test drive the vehicle until it is diagnosed and repaired. Refer to «Symptoms - Hydraulic Brakes»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system__symptoms-hydraulic-brakes) .
- Select a smooth, dry, clean and level road or large lot that is as free of traffic and obstacles as possible for brake system low speed road testing.
- With the transmission in PARK, lightly apply the brake pedal. Observe both the pedal feel and the pedal travel.
- If the brake pedal apply felt spongy, or the pedal travel was excessive, DO NOT drive the vehicle until it is repaired.
- If the brake pedal apply did not feel spongy and the pedal travel was not excessive, proceed to step 8.
- Release and apply the brakes.
- While continuing to apply the brakes, shift the transmission into DRIVE, release the brakes and allow the engine to idle the vehicle away from the stopped position. Observe for a slow release of the brake system.
- With the aid of an assistant to observe the vehicle's performance from outside of the vehicle, drive the vehicle at a low speed and lightly apply the brakes while driving past the assistant. Have the assistant observe for brake system noise from the side of the vehicle closest to them, while you observe both the pedal effort and the pedal travel.
- If the brake pedal apply effort was excessive, or the pedal travel was excessive, DO NOT continue to test drive the vehicle until it is repaired.
- If the brake pedal apply effort was not excessive and the pedal travel was not excessive, proceed to step 13.
- Drive the vehicle in the opposite direction, at the same low speed and lightly apply the brakes while driving past the assistant. Have the assistant observe for brake system noise from the side of the vehicle closest to him.
- Drive the vehicle at a low speed and shift the transmission into NEUTRAL without applying the brakes. Observe for a rapid deceleration in vehicle speed, indicating possible brake drag.
- Select a smooth, dry, clean and level road that is as free of heavy traffic as possible for brake system moderate speed road testing.
- Drive the vehicle at a moderate speed. Observe for a pull and/or incorrect tracking of the vehicle without the brakes applied.
- While continuing to drive the vehicle at a moderate speed, perform several light applies of the brakes. Observe the pedal effort and the pedal travel, observe for brake system noise, pulsation and/or brake drag.
- If the brake pedal apply effort was excessive, or the pedal travel was excessive, DO NOT continue to test drive the vehicle until it is repaired.
- If the brake pedal apply effort was not excessive and the pedal travel was not excessive, proceed to step 20.
- While continuing to drive the vehicle at a moderate speed, perform several moderate applies of the brakes. Observe the pedal effort and the pedal travel, observe for brake system pulsation and/or uneven braking action - either side to side, or front to rear. A small amount of vehicle front end dip is expected during a moderate apply of the brakes.
- If the brake pedal apply effort was excessive, or the pedal travel was excessive, DO NOT continue to test drive the vehicle until it is repaired.
Special Tools
- With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve.
- Install the J 28662 to the brake pedal. See «Special Tools»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) .
- Measure and record the distance (1) from the brake pedal to the rim of the steering wheel; note the points of measurement.
- Apply and maintain the brakes with 445 N (100 lb) of force to the brake pedal, as indicated on the J 28662 . See «Special Tools»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) .
- While maintaining 445 N (100 lb) of force to the brake pedal, measure and record the distance (2) from the same point on the brake pedal to the same point on the rim of the steering wheel.
- Release the brakes and repeat steps 4 and 5 to obtain a second measurement. After obtaining a second measurement, proceed to step 7.
- Average the first and second measurements recorded during the two applies of the brakes.
- Subtract the initial measurement, unapplied (1), from the averaged, applied measurement (2) to obtain the brake pedal travel distance. Specification: Vacuum assist equipped, maximum brake pedal travel (measured with the ignition OFF, brake booster power assist depleted, and the brakes cool): 60 mm (2.36 in) Hydraulic assist equipped, maximum brake pedal travel (measured with the ignition OFF, brake booster power assist depleted, and the brakes cool): 90 mm (3.54 in)
Brake Pedal Travel Measurement and Inspection (Two-mode Hybrid)
Note. The brake corners must be cool to obtain the most accurate measurement.
- Place the transmission in PARK.
- Turn the ignition OFF, without pausing at ACCESSORY, and without applying the brake pedal. Remove the ignition key.
- Wait approximately 1-3 minutes until the brake modulator and HPA pressure relief is complete.
- Inspect the battery state of charge. Refer to «Battery Inspection/Test»(/cadillac/escalade/gmt900-2006-2014/remont/charging-system/#battery-charging-system-and-starting-system) .
- If necessary, connect a battery charger to the 12V battery. Refer to «Battery Charging»(/cadillac/escalade/gmt900-2006-2014/remont/charging-system/#battery-charging-system-and-starting-system) .
- Install a scan tool to the vehicle.
- Turn the ignition ON with the engine OFF.
- Using the scan tool, perform the following steps: Select Diagnostics Select the appropriate vehicle information Select Chassis Select Electronic Brake Control Module (EBCM) Select Data Display Scroll through the Data List, select and accept Brake Master Cylinder (BMC) Primary Piston Reference Position, and Master Cylinder Pressure Sensor
- While observing the master cylinder pressure on the scan tool data display, using moderate speed and moderate effort, press the brake pedal to a force of 5000 kPa (725 psi).
- Record the distance the displayed on the scan tool that the BMC primary piston has travelled at a pedal apply force of 5000 kPa (725 psi).
- Release the brake pedal.
- Wait 15 seconds, then repeat steps 9-11 to obtain a second measurement.
- Compute the average of the first and second measurements recorded during the brake applies. Specification: Maximum brake master cylinder (BMC) primary piston travel, (measured with the ignition ON, engine OFF and the brakes cool), at a brake pedal apply force of 5000 kPa (725 psi): 18 mm (0.71 in)
Brake System Vacuum Source Test
- Disconnect the engine vacuum hose from the vacuum brake booster check valve.
- Install a vacuum gauge to the engine vacuum hose.
- Start the engine and allow the engine to idle until normal operating temperatures are reached.
- With the vehicle in PARK, the engine idling, and the air conditioning (A/C) system OFF, check to see if the engine vacuum reading is within the specified normal engine vacuum range. Specification: 47-68 kPa (14-20 in Hg)
- Turn the ignition OFF.
- If the engine vacuum reading was within the specified normal range, proceed to step 10.
- If the engine vacuum reading was NOT within the specified normal range, inspect the engine vacuum hose for the following conditions: Loose connection to the engine Collapse, deformation or contamination Cracks, cuts, dry-rot
- If any of these conditions were found with the engine vacuum hose, replace the hose, then repeat steps 2-4.
- If none of these conditions were found with the engine vacuum hose, then there is an engine vacuum source problem, check the engine vacuum system.
- Remove the vacuum brake booster check valve from the booster.
- Install the check valve to the engine vacuum hose.
- Install the vacuum gauge to the check valve.
- Start the engine and allow the engine to idle in PARK with the A/C system OFF, until normal operating temperatures are reached.
- Turn the ignition OFF.
- Check to see if the engine vacuum reading is maintained within the specified normal engine vacuum range. Specification: 47-68 kPa (14-20 in Hg)
- If the engine vacuum reading is maintained within the specified normal range, proceed to step 18.
- If the engine vacuum reading is NOT maintained within the specified normal range, replace the brake booster check valve, then repeat steps 11-15.
- Inspect the brake booster check valve grommet for the following conditions: Loose connection to the vacuum brake booster Deformation or contamination Cracks, cuts, dry-rot
- If any of these conditions were found with the check valve grommet, replace the grommet.
Scheme 2
Scheme 2: Hydraulic Brake Booster Leak Inspection
- Check the power steering system fluid level and adjust as necessary. Refer to «Checking and Adding Power Steering Fluid (Without Hydroboost)»(/cadillac/escalade/gmt900-2006-2014/remont/electronic-steering/#power-steering-system__checking-and-adding-power-steering-fluid) or «Checking and Adding Power Steering Fluid (With Hydroboost)»(/cadillac/escalade/gmt900-2006-2014/remont/electronic-steering/#power-steering-system__checking-and-adding-power-steering-fluid) .
- Clean any fluid from the following areas: The power steering hose fittings (1) The power steering hose ports (3) The joint between the power brake booster housing and end cap (4) The joint between the power brake booster housing and the master cylinder (5) The end cap The power steering inlet and outlet hoses at the crimp joints (6)
- Start the engine and allow the power steering fluid to reach operating temperature.
- Allow the engine to idle and slowly apply the brake pedal to run-out, holding until the power steering pump reaches the pressure relief valve setting and hisses. Maintain the brake pedal force approximately two seconds, then release the brake pedal.
- With the brakes fully released, allow the engine to idle for fifteen seconds.
- Repeat steps 4 and 5 four times.
- With the engine idling, turn the steering wheel from stop to stop four times holding the steering wheel at each stop for two seconds.
- Increase the engine speed to approximately 1,000 RPM and turn the steering wheel approximately every one second. Do not hold the steering wheel at full stop.
- Allow the engine to idle without pressure applied to the brake pedal for thirty seconds.
- With the engine idling, apply the brake pedal to run-out and hold the pedal force at run-out for approximately one second and then release the brake pedal.
- Repeat steps 7 through 10 four times.
- Allow the engine to idle for thirty seconds and then turn the engine OFF.
- Inspect the power brake booster, the power steering hose fitting ports (3), and the power steering inlet and outlet hoses at the crimp joints (6) for any leaks.
- If there are leaks at the power steering inlet and/or outlet hoses at the crimp joints, the affected power steering hose requires replacement.
- If there are leaks at the power steering hose fittings (1) to the hydraulic booster ports (3), perform the following steps: Tighten the leaking power steering hose assembly fittings to the proper specifications Inspect again for fluid leaks at the affected locations
- If there are leaks at the power steering hose fittings after tightening the fittings, perform the following steps: At each affected location, disconnect the power steering hose fitting Inspect the sealing end of the power steering hose fitting for damage and replace the hose if damaged Install a new O-ring seal (2) to the power steering hose Install the power steering hose and tighten the fitting to the proper specification Inspect again for fluid leaks at the affected location
- If the power brake booster is leaking, replace the power brake booster. Refer to «Power Brake Booster Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system__power-brake-booster-replacement) .
- If brake fluid is leaking, refer to «Brake Fluid Loss»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system__brake-fluid-loss) .
Tools Required
Inspection
- Install the J 28662 to the brake pedal. See «Special Tools»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) .
- Start the engine and allow it to idle. Ensure that the wheels are directed straight ahead.
- Apply and maintain the brakes with 111 N (25 lb) of force to the brake pedal, as indicated on the J 28662 . See «Special Tools»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) . Observe for noises.
- Quickly release the brakes. Observe for noises.
- If chatter and/or a vibration of the brake pedal was apparent during the brake system apply of 111 N (25 lb) of force, the power steering pump drive belt not may have proper tension or may be excessively worn.
- If any significant noise was apparent during the quick release of the brakes following the brake system apply of 111 N (25 lb) of force, there is likely a restriction in the hydraulic brake booster power steering return hose.
- Apply the brakes with 178 N (40 lb) of force to the brake pedal, as indicated on the J 28662 , then gradually increase pedal effort up to 445 N (100 lb) of force for not more than 5 seconds at a time. See «Special Tools»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) . Observe for noises.
- Quickly release the brakes. Observe for noises.
- If a hiss noise was apparent and increased during the brake system increasing apply of 178-445 N (40-100 lb) of force, the hydraulic brake booster assist system is operating normally from an audible standpoint.
- If a clunk, chatter, and/or clicking noise was apparent during the quick release of the brakes following the brake system increasing apply of 178-445 N (40-100 lb) of force, the hydraulic brake booster assist system is operating normally from an audible standpoint.
Brake System External Leak Inspection
- In order to inspect for external brake fluid leaks, first check the fluid level in the master cylinder. While a slight brake fluid level drop can be considered a normal condition due to brake lining wear, a very low level may indicate a brake fluid leak in the hydraulic system.
- If the fluid level is abnormally low, adjust the brake fluid level. Refer to «Master Cylinder Reservoir Filling»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system__master-cylinder-reservoir-filling) .
- Start the engine and allow it to idle.
- Apply constant, moderate foot pressure to the brake pedal. If the brake pedal gradually falls away while under foot pressure, there may be a brake fluid leak.
- Turn OFF the ignition.
- Visually inspect the following brake system components for brake fluid leaks, excessive corrosion, and damage. Give particular attention to all brake pipe and flexible hose connections to ensure that there are not any slight brake fluid leaks - even though the brake pedal may feel firm and hold steady: Master cylinder brake pipe fittings All brake pipe connections Brake pipes Brake hoses and connections Brake calipers and/or wheel cylinders, if equipped
- While slight dampness around the master cylinder reservoir can be considered acceptable, brake fluid leaking from any of the brake system components requires immediate attention. If any of these components exhibit signs of brake fluid leakage, repair or replace those components. After the repair or replacement, reinspect the hydraulic brake system to assure proper function.
Brake System Internal Leak Test (Two-mode Hybrid)
- Ensure is ignition is OFF for at least 60 seconds to allow the system to depressurize and deplete the power reserve.
- Apply the brake pedal several times to verify the power reserve is fully depleted.
- Apply light, steady pressure to the brake pedal. Observe both the brake pedal feel and travel.
- Release the brake pedal.
- If the brake pedal apply felt spongy, but the brake pedal travel was not excessive, perform the following steps: Inspect the brake system for external leaks. Refer to «Brake System External Leak Inspection»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system__brake-system-external-leak-inspection) . Pressure bleed the brake system in order to purge any air that may be trapped in the system. Refer to «Hydraulic Brake System Bleeding (Manual)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) «Hydraulic Brake System Bleeding (Pressure)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) .
- If the brake pedal apply did not feel spongy, but the brake pedal travel was excessive, perform the following steps: Loosen the master cylinder-to-adapter mounting nuts. Carefully pull the master cylinder away from the adapter just enough to inspect the mounting surface of the master cylinder. Inspect the master cylinder mounting surface at the primary piston (2) for brake fluid leaks.
- If the master cylinder exhibits any leakage around the primary piston (2), then the primary piston primary seal (4) and/or secondary seal (3) is leaking and the master cylinder requires replacement.
- If the master cylinder primary piston (2) does not exhibit any leakage, install the master cylinder to the adapter and pressure bleed the brake system. Refer to «Hydraulic Brake System Bleeding (Manual)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) or «Hydraulic Brake System Bleeding (Pressure)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) .
- If the brake pedal apply did not feel spongy, and the brake pedal travel was initially steady and not excessive, but then gradually fell, then the master cylinder requires replacement due to an internal leak past a piston seal.
- If the brake pedal apply did not feel spongy, and the brake pedal travel was initially steady and not excessive, then fell slightly, then became steady again, then the brake pressure modulator valve (BPMV) may be leaking internally, and may require replacement.
Brake System Internal Leak Test (Non-Hybrid)
- Start the engine and allow it to idle.
- Apply light, steady pressure to the brake pedal. Observe both the brake pedal feel and travel.
- Release the brakes and turn OFF the ignition.
- If the brake pedal apply felt spongy, but the brake pedal travel was not excessive, perform the following steps: Inspect the brake system for external leaks. Refer to «Brake System External Leak Inspection»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system__brake-system-external-leak-inspection) . Pressure bleed the brake system in order to purge any air that may be trapped in the system. Refer to «Hydraulic Brake System Bleeding (Manual)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) «Hydraulic Brake System Bleeding (Pressure)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) .
- If the brake pedal apply did not feel spongy, but the brake pedal travel was excessive, perform the following steps: Loosen the master cylinder-to-brake power booster mounting nuts. Carefully pull the master cylinder away from the brake power booster just enough to inspect the mounting surface of the master cylinder. Inspect the master cylinder mounting surface at the primary piston (2) for brake fluid leaks.
- If the master cylinder exhibits any leakage around the primary piston (2), then the primary piston primary seal (4) and/or secondary seal (3) is leaking and the master cylinder requires overhaul or replacement.
- If the master cylinder primary piston (2) does not exhibit any leakage, pressure bleed the brake system. Refer to «Hydraulic Brake System Bleeding (Manual)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) or «Hydraulic Brake System Bleeding (Pressure)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) .
- If the brake pedal apply did not feel spongy, and the brake pedal travel was initially steady and not excessive, but then gradually fell, then the master cylinder requires overhaul or replacement due to an internal leak past the secondary piston (1) from the secondary piston primary seal (6) or secondary seal (5).
- If the brake pedal apply did not feel spongy, and the brake pedal travel was initially steady and not excessive, then fell slightly, then became steady again, then the brake pressure modulator valve (BPMV) may be leaking internally, and may require replacement.
Hydraulic Brake Component Operation Visual Inspection
- With the tire and wheel assemblies removed and the brake rotors retained by wheel lug nuts, visually inspect the caliper piston dust boot (2) sealing area to ensure that there are no brake fluid leaks.
- If any evidence of a brake fluid leak is present, the brake caliper requires overhaul or replacement.
- While the brake system is at rest (4), observe the position of the caliper piston (1) in relation to the caliper housing.
- Have an assistant apply and release the brake pedal several times while you observe the operation of the hydraulic brake caliper. Observe the caliper piston (1) for unrestricted and even movement during each apply of the brake system (5). Observe the caliper piston (1) for an unrestricted and even return motion during each release of the brake system (6).
- If the caliper piston (1) did not exhibit unrestricted and even movement during brake system apply and/or release, the piston square seal (3) may be worn or damaged and the caliper may require overhaul or replacement.
Brake Pipe and Hose Inspection
- Visually inspect all of the brake pipes for the following conditions: Kinks, improper routing, missing or damaged retainers Leaking fittings, excessive corrosion
- If any of the brake pipes exhibited any of the conditions listed, then the identified pipe, or pipes, require replacement.
- Ensure that the vehicle axles are properly supported at ride height in order to maintain the proper relationship of the flexible brake hoses to the chassis.
- Visually inspect all of the flexible brake hoses for the following conditions: Kinks (1), improper routing, twists, chafing, missing or damaged retainers Leaking connections, cracking, dry-rot, blisters, bulges
- If any of the flexible brake hoses exhibited any of the conditions listed, then the identified flexible brake hose, or hoses require replacement.
- Squeeze the flexible brake hoses with firm finger pressure to check for soft spots (2), indicating an internal restriction. Check the entire length of each flexible brake hose.
- If any of the flexible brake hoses were found to have soft spots (2), then the identified flexible brake hose, or hoses require replacement.
Brake Pedal Pushrod Inspection
- Disconnect the brake pedal pushrod (1) from the brake pedal.
- Inspect the brake pedal pushrod eyelet bushing (2), if equipped, for cracks and/or excessive wear.
- Reposition the pedal pushrod boot (3) toward the front of the vehicle to expose as much of the pedal pushrod (1) as possible.
- Inspect the brake pedal pushrod (1) for straightness.
- If the brake pedal pushrod eyelet bushing (2) exhibited cracks and/or excessive wear, then the bushing requires replacement.
- If the brake pedal pushrod (1) is not straight, then the pushrod requires replacement.
- Return the pedal pushrod boot (3) to its original position on the pedal pushrod (1).
- Connect the brake pedal pushrod (1) to the brake pedal.
Master Cylinder Reservoir Filling
| CAUTION | When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. |
- Visually inspect the brake fluid level through the brake master cylinder reservoir.
- If the brake fluid level is at or below the half-full point during routine fluid checks, the brake system should be inspected for wear and possible brake fluid leaks.
- If the brake fluid level is at or below the half-full point during routine fluid checks, and an inspection of the brake system did not reveal wear or brake fluid leaks, the brake fluid may be topped-off up to the maximum-fill level.
- If brake system service was just completed, the brake fluid may be topped-off up to the maximum-fill level.
- If the brake fluid level is above the half-full point, adding brake fluid is not recommended under normal conditions.
- If brake fluid is to be added to the master cylinder reservoir, clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. Use only Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
Removal Procedure
- Turn the ignition to OFF, without pausing at ACCESSORY, and remove the ignition key.
- Wait approximately 1 to 3 minutes until the brake modulator and HPA pressure relief is complete.
- Remove the brake fluid from the brake master cylinder reservoir and discard into an approved container.
- Disconnect the brake fluid level sensor electrical connector.
- Disconnect the brake master cylinder reservoir return hose quick connect (1) and position the hose aside.
- Disconnect the brake master cylinder reservoir supply hose quick connect (2) and position the hose aside.
- Remove the brake master cylinder reservoir pins (1).
- Lift the master cylinder reservoir (1) straight up and remove the reservoir from the master cylinder.
- Remove the 3 master cylinder reservoir seals (1).
Installation Procedure
- Install the 3 master cylinder reservoir seals (1). Lubricate the master cylinder reservoir seals and the outer surface area of the reservoir-to-housing barrels with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
- Install the master cylinder reservoir (1) to the master cylinder. Ensure the master cylinder reservoir is seated fully into the master cylinder by pressing the reservoir straight down into the master cylinder.
- Install the brake master cylinder reservoir pins (1) and tighten to 8 N.m (71 lb in).
- Connect the brake master cylinder reservoir return hose quick connect (1).
- Connect the brake master cylinder reservoir supply hose quick connect (2).
- Connect the brake fluid level sensor electrical connector.
- Fill the brake master cylinder reservoir. Refer to «Master Cylinder Reservoir Filling»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system__master-cylinder-reservoir-filling) .
Scheme 3
Scheme 3: Master Cylinder Reservoir Replacement (JD9)
| Callout | Component Name |
| WARNING: Refer to Brake Fluid Irritant Warning . CAUTION: Refer to Brake Fluid Effects on Paint and Electrical Components Caution . Preliminary Procedures Using a suitable tool, remove the brake fluid from the brake master cylinder reservoir. Discard the brake fluid into an approved container. |
| 1 | Master Cylinder Fluid Level Sensor Electrical Connector |
| 2 | Master Cylinder Reservoir Procedure: Carefully spread the 2 locking tabs and lift the master cylinder reservoir upward. |
| 3 | Master Cylinder Reservoir Seals (Qty: 2) Tip: Lubricate the seals and the outer surface area of the reservoir-to-housing barrels with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. |
- Using a suitable tool, remove the brake fluid from the brake master cylinder reservoir.
- Discard the brake fluid into an approved container.
- Disconnect the brake fluid level indicator switch electrical connector.
- Remove the master cylinder reservoir bolts (1).
- Carefully lift the master cylinder reservoir (1) straight upward and remove the reservoir from the master cylinder.
- Remove the master cylinder reservoir seals (1).
- Lubricate the master cylinder reservoir seals (1) and the outer surface area of the reservoir-to-housing barrels with GM approved brake fluid from a clean, sealed brake fluid container.
- If reinstalling the master cylinder reservoir, clean the reservoir with denatured alcohol, or equivalent and allow to dry.
- Install the master cylinder reservoir seals to the master cylinder. Ensure the master cylinder reservoir seals are fully seated in the master cylinder body.
- Lubricate the master cylinder reservoir-to-master cylinder barrels with GM approved brake fluid from a clean, sealed brake fluid container.
- Carefully press the master cylinder reservoir (1) straight downward and install the reservoir to the master cylinder.
- Install the master cylinder reservoir bolts (1) and tighten to 8 N.m (71 lb in).
- Connect the brake fluid level indicator switch electrical connector.
- Fill the master cylinder reservoir. Refer to «Master Cylinder Reservoir Filling»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system__master-cylinder-reservoir-filling) .
Scheme 4
Scheme 4: Master Cylinder Replacement (JD9)
| Callout | Component Name |
| WARNING: Refer to Brake Fluid Irritant Warning . CAUTION: Refer to Brake Fluid Effects on Paint and Electrical Components Caution . Preliminary Procedures With the engine OFF, apply the brake pedal several times until the brake pedal becomes firm to deplete the vacuum brake booster vacuum reserve. Using a suitable tool, remove the brake fluid from the brake master cylinder reservoir. Discard the brake fluid into an approved container. |
| 1 | Master Cylinder Fluid Level Sensor Electrical Connector |
| 2 | Brake Pipe Fitting (Qty: 2) CAUTION: Refer to Fastener Caution . Procedure Remove any dirt or debris from the brake pipe fitting. Cap the brake pipe fittings to prevent brake fluid loss and contamination. Tighten: 32 N.m (24 lb ft) |
| 3 | Brake Master Cylinder Nut (Qty: 2) Tighten: 36 N.m (27 lb ft) |
| 4 | Brake Master Cylinder Assembly |
| 5 | Brake Master Cylinder to Vacuum Booster Seal Procedure Inspect the brake master cylinder to vacuum booster seal for damage and replace if necessary. Ensure the brake master cylinder to vacuum booster seal is properly seated against the base of the brake master cylinder. Do not place the brake master cylinder to vacuum booster seal in the groove of the master cylinder body. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System Bleeding (Pressure) . |
Scheme 5
Scheme 5: Master Cylinder Replacement (JH6)
| Callout | Component Name |
| WARNING: Refer to Brake Fluid Irritant Warning . CAUTION: Refer to Brake Fluid Effects on Paint and Electrical Components Caution . Preliminary Procedures Using a suitable tool, remove the brake fluid from the brake master cylinder reservoir. Discard the brake fluid into an approved container. Disconnect the brake fluid pressure sensor electrical connector, if equipped. |
| 1 | Master Cylinder Fluid Level Sensor Electrical Connector |
| 2 | Brake Pipe Fitting (Qty: 2) CAUTION: Refer to Fastener Caution . Procedure Remove any dirt or debris from the brake pipe fitting. Cap the brake pipe fittings to prevent brake fluid loss and contamination. Tighten: 32 N.m (24 lb ft) |
| 3 | Brake Master Cylinder Nut (Qty: 2) Tighten: 36 N.m (27 lb ft) |
| 4 | Brake Master Cylinder Assembly Procedure Remove and discard the push-on nuts on the master cylinder mounting studs, if equipped. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System Bleeding (Pressure) . |
- Turn the ignition to OFF, without pausing at ACCESSORY, and remove the ignition key.
- Wait approximately 1 to 3 minutes until the brake modulator and HPA pressure relief is complete.
- Remove the brake fluid from the brake master cylinder reservoir and discard into an approved container.
- Disconnect the brake fluid level sensor electrical connector.
- Disconnect the brake master cylinder reservoir return hose quick connect (1) and position the hose aside.
- Disconnect the brake master cylinder reservoir supply hose quick connect (2) and position the hose aside.
- Disconnect the brake master cylinder primary brake pipe fitting (1). Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination.
- Disconnect the brake master cylinder left supply brake pipe fitting (1). Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination.
- Disconnect the brake master cylinder right supply brake pipe fitting (1). Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination.
- Disconnect the brake master cylinder right front brake pipe fitting (1). Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination.
- Disconnect the brake master cylinder left front brake pipe fitting (1). Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination.
- Remove the brake master cylinder nuts (1). Discard the brake master cylinder nuts.
- Remove the brake master cylinder and the master cylinder seal (1).
- Bench bleed the master cylinder. Refer to «Master Cylinder Bench Bleeding»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system__master-cylinder-bench-bleeding) .
- Install the brake master cylinder seal (1) and the master cylinder to the adapter. Ensure the brake master cylinder seal is fully seated in the groove on the master cylinder housing.
- Install 2 new brake master cylinder nuts (1) and tighten to 33 N.m (24 lb ft).
- Connect the brake master cylinder left front brake pipe fitting (1) and tighten to 30 N.m (22 lb ft).
- Connect the brake master cylinder right front brake pipe fitting (1) and tighten to 30 N.m (22 lb ft).
- Connect the brake master cylinder right supply brake pipe fitting (1) and tighten to 30 N.m (22 lb ft).
- Connect the brake master cylinder left supply brake pipe fitting (1) and tighten to 30 N.m (22 lb ft).
- Connect the brake master cylinder primary brake pipe fitting (1) and tighten to 30 N.m (22 lb ft).
- Connect the brake master cylinder reservoir return hose quick connect (1).
- Connect the brake master cylinder reservoir supply hose quick connect (2).
- Connect the brake fluid level sensor electrical connector.
- Fill the brake master cylinder reservoir. Refer to «Master Cylinder Reservoir Filling»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system__master-cylinder-reservoir-filling) .
- Bleed the hydraulic brake system. Refer to «Hydraulic Brake System Bleeding (Manual)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) or «Hydraulic Brake System Bleeding (Pressure)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) .
- Place the transmission in the PARK or NEUTRAL position.
- Apply the park brake.
- Turn the ignition to OFF, without pausing at ACCESSORY, and without applying the brake pedal. Remove the ignition key.
- Wait approximately 1 to 3 minutes until the brake modulator and HPA pressure relief is complete.
- Remove the master cylinder nuts (1). Discard the master cylinder nuts.
- Without disconnecting the brake pipes, release and carefully position aside the master cylinder (1). Support the master cylinder with heavy mechanics wire or equivalent.
- Inspect the master cylinder seal (1) for damage and replace, if necessary.
- Disconnect the brake master cylinder (BMC) primary piston position sensor electrical connector.
- Remove the brake pushrod retainer bolt (1), if equipped.
- Remove the brake pushrod retainer (1).
- Slide the stoplamp switch (1) off of the brake pedal pushrod pin while simultaneously disconnecting the brake pushrod.
- Remove the 4 brake pedal bracket nuts (1).
- Remove the brake master cylinder adapter (1).
- Inspect the master cylinder adapter gasket for damage and replace, if necessary.
- Install the master cylinder adapter gasket, if removed.
- Install the brake master cylinder adapter (1).
- Install the 4 brake pedal bracket nuts (1) and tighten to 25 N.m (18 lb ft).
- Connect the brake pedal pushrod while simultaneously installing the stoplamp switch (1).
- Install the brake pushrod retainer (1). Rotate the brake pushrod retainer 360 degrees to ensure the retainer is fully engaged in the brake pedal pushrod pivot pin groove.
- Install the brake pushrod retainer bolt (1), if equipped and tighten to 10 N.m (89 lb in).
- Connect the BMC primary piston position sensor electrical connector.
- Install the master cylinder seal (1), if removed. Ensure the brake master cylinder seal is fully seated in the groove on the master cylinder housing.
- Position the master cylinder (1) to the master cylinder adapter.
- Install 2 new master cylinder nuts (1) and tighten to 33 N.m (24 lb ft).
- Inspect the battery state of charge. Refer to «Battery Inspection/Test»(/cadillac/escalade/gmt900-2006-2014/remont/charging-system/#battery-charging-system-and-starting-system) .
- If necessary, connect a battery charger to the 12V battery. Refer to «Battery Charging»(/cadillac/escalade/gmt900-2006-2014/remont/charging-system/#battery-charging-system-and-starting-system) .
- Install a scan tool to the vehicle.
- Turn the ignition ON with the engine OFF.
- Using the scan tool, perform the following steps: Select Diagnostics Select the appropriate vehicle information Select Chassis Select Electronic Brake Control Module (EBCM) Select Module Setup Select BMC Primary Piston Position Relearn and follow the instructions on the scan tool
Master Cylinder Bench Bleeding
- Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible.
- Remove the master cylinder reservoir cap and diaphragm.
- Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment.
- Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir.
- Fill the master cylinder reservoir to at least the half-way point with GM approved brake fluid from a clean, sealed brake fluid container. Refer to «Master Cylinder Reservoir Filling»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system__master-cylinder-reservoir-filling) .
- Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid.
- Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 in), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease.
- Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles.
- Remove the transparent hoses from the master cylinder reservoir.
- Install the master cylinder reservoir cap and diaphragm.
- Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills.
- Remove the master cylinder from the vise.
Scheme 6
Scheme 6: Brake Fluid Level Indicator Switch Replacement (Two-mode Hybrid)
| Callout | Component Name |
| Preliminary Procedures Place the ignition switch in the OFF position. Disconnect the brake fluid level sensor electrical connector. |
| 1 | Brake Fluid Level Sensor Tip: Compress the brake fluid level sensor locking tabs on the opposite side of the master cylinder reservoir to remove. |
Scheme 7
Scheme 7: Brake Fluid Level Indicator Switch Replacement (JD9, JH6)
| Callout | Component Name |
| Preliminary Procedure: Disconnect the master cylinder fluid level sensor electrical connector. |
| 1 | Master Cylinder Fluid Level Sensor Tip: Compress the locking tabs on the sensor to release the sensor from the brake master cylinder reservoir. |
Scheme 8
Scheme 8: Brake Pedal Assembly Replacement
| Callout | Component Name |
| Preliminary Procedure: Apply the park brake. |
| 1 | Brake Booster Pushrod Retainer Bolt (if equipped) CAUTION: Refer to Fastener Caution . Tighten: 10 N.m (89 lb in) |
| 2 | Brake Booster Pushrod Retainer Procedure: After installing the retainer to the pushrod pin on the brake pedal, rotate the retainer 360 degrees to ensure it is seated properly before tightening the retainer bolt. |
| 3 | Stoplamp Switch |
| 4 | Brake Booster Pushrod Procedure: For reassembly, apply a thin coat of high temperature grease GM P/N 12345994 (Canadian P/N 10953501) to the pushrod pin on the brake pedal. |
| 5 | Brake Pedal Pivot Nut Procedure: Hold the brake pedal pivot bolt stationary and tighten the brake pedal pivot nut. Tighten: 35 N.m (26 lb ft) |
| 6 | Brake Pedal Pivot Bolt |
| 7 | Brake Pedal Procedure If installing a new brake pedal pivot bushing, ensure the conical flange end of the bushing is on the inboard side of the pedal. For installation, apply high temperature grease GM P/N 12345994 (Canadian P/N 10953501) to the ID of the brake pedal pivot bushing. |
Replacement
- Inspect the area of brake pipe to be repaired or replaced.
- Release the brake pipe to be replaced from the retainers, as required.
- Select an appropriate location to section the brake pipe, if necessary. Allow adequate clearance in order to maneuver the J 45405 . See «Special Tools»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) . Avoid sectioning the brake pipe at bends or mounting points.
- Using a string or wire, measure the length of the pipe to be replaced including all pipe bends.
- Add to the measurement taken the appropriate additional length required for each flare to be created. Specification: 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe 9.50 mm (0.374 in) for 6.35 mm (1/4 in) diameter pipe 12.67 mm (0.499 in) for 7.94 mm (5/16 in) diameter pipe
- Using the pipe cutter included in the J 45405 , carefully cut the brake pipe squarely to the measured length. See «Special Tools»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) .
- Remove the sectioned brake pipe from the vehicle.
- Select the appropriate size of brake pipe and tube nuts, as necessary. The brake pipe outside diameter determines brake pipe size.
- Strip the nylon coating from the brake pipe end to be flared, if necessary. Select the appropriate blade on the coating stripping tool included in the J 45405 , by unthreading the blade block from the stripping tool and installing the block with the desired blade facing the tool rollers. See «Special Tools»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) . Specification: 6.35 mm (0.250 in) blade for 4.76 mm (3/16 in) diameter pipe 9.50 mm (0.374 in) blade for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe Insert the brake pipe end to be flared into the stripping tool to the depth of the ledge on the tool rollers. While holding the brake pipe firmly against the stripping tool roller ledges, rotate the thumbwheel of the tool until the blade contacts the brake pipe coated surface. NOTE: Do not gouge the metal surface of the brake pipe. Rotate the stripping tool in a clockwise direction, ensuring that the brake pipe end remains against the tool roller ledges. After each successive revolution of the stripping tool, carefully rotate the thumbwheel of the tool clockwise, in order to continue stripping the coating from the brake pipe until the metal pipe surface is exposed. Loosen the thumbwheel of the tool and remove the brake pipe. NOTE: Ensure that all loose remnants of the nylon coating have been removed from the brake pipe. Inspect the stripped end of the brake pipe to ensure that the proper amount of coating has been removed. Specification: 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe 9.50 mm (0.374 in) for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe
- Chamfer the inside and outside diameter of the pipe with the de-burring tool included in the J 45405 . See «Special Tools»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) .
- Install the tube nuts on the brake pipe, noting their orientation.
- Clean the brake pipe and the J 45405 of lubricant, contaminants, and debris. See «Special Tools»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) .
- Loosen the die clamping screw of the J 45405 . See «Special Tools»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) .
- Select the corresponding die set and install the die halves into the die cage with the full, flat face of one die facing the clamping screw, and the counterbores of both dies facing the forming ram.
- Place the flat face of an unused die (1) against the die halves in the clamping cage and hold firmly against the counterbored face of the dies.
- Insert the prepared end of the pipe to be flared through the back of the dies until the pipe is seated against the flat surface of the unused die (1).
- Remove the unused die (1).
- Ensure that the rear of both dies are seated firmly against the enclosed end of the die cage.
- Firmly hand tighten the clamping screw (2) against the dies.
- Select the appropriate forming mandrel and place into the forming ram.
- Rotate the hydraulic fluid control valve clockwise to the closed position.
- Rotate the body of the J 45405 until it bottoms against the die cage. See «Special Tools»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) .
- While guiding the forming mandrel into the exposed end of pipe to be flared, operate the lever of the J 45405 until the forming mandrel bottoms against the clamping dies. See «Special Tools»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) .
- Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the hydraulic forming ram to retract.
- Insert the finishing cone into the forming ram.
- Rotate the hydraulic fluid control valve clockwise to the closed position.
- Rotate the body of the J 45405 until it bottoms against the die cage. See «Special Tools»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) .
- While guiding the finishing cone into the exposed end of pipe to be flared, operate the lever of the J 45405 until the finishing cone bottoms against the dies. See «Special Tools»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) .
- Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the hydraulic forming ram to retract.
- Loosen the die clamping screw and remove the dies and pipe.
- If necessary, lightly tap the dies until the die halves separate.
- Inspect the brake pipe flare for correct shape and diameter (a). Specification: 6.74-7.10 mm (0.265-0.279 in) flare diameter for 4.76 mm (3/16 in) diameter pipe 8.57-9.27 mm (0.344-0.358 in) flare diameter for 6.35 mm (1/4 in) diameter pipe 10.42-10.79 mm (0.410-0.425 in) flare diameter for 7.94 mm (5/16 in) diameter pipe
- If necessary, using the removed section of brake pipe as a template, shape the new pipe with a suitable brake pipe bending tool. NOTE: When installing the pipe, maintain a clearance of 19 mm (3/4 in) from all moving or vibrating components.
- Install the pipe to the vehicle with the appropriate brake pipe unions, as required.
- If previously released, secure the brake pipe to the retainers.
- Bleed the hydraulic brake system. Refer to «Hydraulic Brake System Bleeding (Manual)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) or «Hydraulic Brake System Bleeding (Pressure)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) .
- With the aid of an assistant, inspect the brake pipe flares for leaks by starting the engine and applying the brakes.
- Turn the ignition to OFF, without pausing at ACCESSORY, and remove the ignition key.
- Wait approximately 1 to 3 minutes until the brake modulator and HPA pressure relief is complete.
- Remove the brake fluid from the brake master cylinder reservoir until the level is below the reservoir supply hose fitting and discard into an approved container.
- Disconnect the brake fluid level sensor electrical connector.
- Disconnect the brake master cylinder reservoir return hose quick connect (1).
- Disconnect the brake master cylinder reservoir supply hose quick connect (2).
- Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/cadillac/escalade/gmt900-2006-2014/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
- Remove the antilock brake system (ABS) module splash shield retainers (1).
- Remove the ABS module splash shield bolts (1).
- Remove the ABS module splash shield (1).
- Clean all dirt and debris from the brake pressure modulator valve (BPMV) assembly and the brake hose fittings.
- Disconnect the BPMV supply hose quick connect (1). Cap the BPMV inlet port and plug the supply hose to prevent brake fluid loss and contamination.
- Disconnect the BPMV return hose quick connect (1). Cap the BPMV outlet port and plug the return hose to prevent brake fluid loss and contamination.
- Release the supply and return hoses from the retainers and remove the hoses from the vehicle.
- Install the supply and return hoses to the vehicle and the retainers.
- Connect the BPMV return hose quick connect (1). Ensure the return hose quick connect is fully engaged by attempting to pull the return hose from the outlet fitting.
- Connect the BPMV supply hose quick connect (1). Ensure the supply hose quick connect is fully engaged by attempting to pull the supply hose from the inlet fitting.
- Install the ABS module splash shield (1).
- Install the ABS module splash shield bolts (1) and tighten to 20 N.m (15 lb ft).
- Install the ABS module splash shield retainers (1).
- Lower the vehicle.
- Connect the brake master cylinder reservoir return hose quick connect (1).
- Connect the brake master cylinder reservoir supply hose quick connect (2).
- Fill the brake master cylinder reservoir. Refer to «Master Cylinder Reservoir Filling»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system__master-cylinder-reservoir-filling) .
Scheme 9
Scheme 9: Front Brake Hose Replacement (JH6)
Scheme 10
Scheme 10: Front Brake Hose Replacement (JD9)
Scheme 11
Scheme 11: Rear Brake Hose Replacement (JH6)
Scheme 12
Scheme 12: Rear Brake Hose Replacement (Frame to Rear Axle JH6)
| Callout | Component Name |
| WARNING: Refer to Brake Dust Warning . WARNING: Refer to Brake Fluid Irritant Warning . Preliminary Procedure: Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . |
| 1 | Brake Pipe Fitting (Qty: 2) CAUTION: Refer to Fastener Caution . Procedure Remove any dirt or debris from the brake pipe fitting. Cap the brake pipe fitting to prevent brake fluid loss and contamination. Tighten: 25 N.m (18 lb ft) |
| 2 | Hose Bracket to Frame Bolt (Qty: 2) Tighten: 25 N.m (18 lb ft) |
| 3 | Brake Pipe Fitting (Qty: 2) Procedure Remove any dirt or debris from the brake pipe fittings. Cap the brake pipe fittings to prevent brake fluid loss and contamination. Tighten: 25 N.m (18 lb ft) |
| 4 | Hose to Rear Axle Bolt Tighten: 25 N.m (18 lb ft) |
| 5 | Rear Brake Hose Assembly Procedure: Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System Bleeding (Pressure) . |
Scheme 13
Scheme 13: Rear Brake Hose Replacement (Frame to Rear Axle JD9)
| Callout | Component Name |
| WARNING: Refer to Brake Fluid Warning . WARNING: Refer to Brake Fluid Irritant Warning . Preliminary Procedure: Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . |
| 1 | Brake Pipe Rear Fitting (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten: 25 N.m (18 lb ft) Tip: Remove any dirt or debris from the brake pipe fitting. Use a backup wrench to hold the brake hose while removing or installing either the brake hose or brake pipe. Cap the brake pipe fitting to prevent brake fluid loss and contamination. |
| 2 | Brake Hose Bracket to Frame Rear Bolt Tighten: 25 N.m (18 lb ft). |
| 3 | Brake Hose to Frame Rear Bracket |
| 4 | Brake Pipe Rear Fitting (Qty: 2) Tip: Remove any dirt or debris from the brake pipe fitting. Use a backup wrench to hold the brake hose while removing or installing either the brake hose or brake pipe. Cap the brake pipe fitting to prevent brake fluid loss and contamination. Tighten: 25 N.m (18 lb ft) |
| 5 | Brake Hose Bracket to Axle Housing Rear Bolt Tighten: 25 N.m (18 lb ft) |
| 6 | Frame to Axle Rear Brake Hose Tip: When installing the brake hose bracket to the axle housing, ensure the brake hose bracket is properly located and properly seated on the rear axle housing mounting bracket. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System Bleeding (Pressure) . |
| 7 | Brake Hose to Rear Axle Housing Bracket |
Scheme 14
Scheme 14: Rear Brake Hose Replacement (JD9)
| Callout | Component Name |
| WARNING: Refer to Brake Fluid Warning . WARNING: Refer to Brake Fluid Irritant Warning . Preliminary Procedures Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation . |
| 1 | Brake Pipe Rear Fitting CAUTION: Refer to Fastener Caution . Tighten: 25 N.m (18 lb ft) Tip: Remove any dirt or debris from the brake pipe fitting. The mounting bracket for the brake hose is serviced as part of the brake hose assembly and is not serviced separately. Use a backup wrench when removing or installing the brake pipe fitting. Cap the brake pipe fitting to prevent brake fluid loss or contamination. |
| 2 | Brake Hose to Axle Rear Bolt Tighten: 9 N.m (80 lb in) Tip: Finger tighten mounting bolt before torquing to the specified value. |
| 3 | Brake Hose to Axle Rear Bracket |
| 4 | Brake Hose to Caliper Rear Bolt Tighten: 40 N.m (30 lb ft) |
| 5 | Brake Hose to Caliper Gasket (Qty: 2) Tip: Make sure the gaskets are not still attached to the brake hose or bolt, if not remove them. DO NOT re-use the gaskets. Install NEW gaskets. |
| 6 | Brake Rear Hose Tip: When installing the brake hose, DO NOT twist or pinch the brake hose. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System Bleeding (Pressure) . |
- Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills.
- With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve.
- If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add GM approved brake fluid from a clean, sealed brake fluid container. Refer to «Fluid and Lubricant Recommendations (USA and Canada)»(/cadillac/escalade/gmt900-2006-2014/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations-usa-and) . If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. Reconnect the brake pipe to the master cylinder port and tighten securely. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. Loosen the same brake pipe to purge air from the open port of the master cylinder. Tighten the brake pipe, then have the assistant slowly release the brake pedal. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened.
- Fill the brake master cylinder reservoir with GM approved brake fluid from a clean, sealed brake fluid container. Refer to «Master Cylinder Reservoir Filling»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system__master-cylinder-reservoir-filling) . Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm.
- Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve.
- Install a transparent hose over the end of the bleeder valve.
- Submerge the open end of the transparent hose into a transparent container partially filled with GM approved brake fluid from a clean, sealed brake fluid container. Refer to «Fluid and Lubricant Recommendations (USA and Canada)»(/cadillac/escalade/gmt900-2006-2014/remont/lubrication-system/#maintenance-and-lubrication__fluid-and-lubricant-recommendations-usa-and) .
- Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal.
- Loosen the bleeder valve to purge air from the wheel hydraulic circuit.
- Tighten the bleeder valve, then have the assistant slowly release the brake pedal.
- Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit.
- With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve.
- Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11.
- With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve.
- Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11.
- With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve.
- Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11.
- After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened.
- Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container. Refer to «Master Cylinder Reservoir Filling»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system__master-cylinder-reservoir-filling) .
- Slowly depress and release the brake pedal. Observe the feel of the brake pedal.
- If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: Inspect the brake system for external leaks. Refer to «Brake System External Leak Inspection»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system__brake-system-external-leak-inspection) . Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system.
- Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated.
- If the brake system warning lamp remains illuminated, refer to «Symptoms - Hydraulic Brakes»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system__symptoms-hydraulic-brakes) .
- J-29532: Diaphragm Pressure Bleeder, or equivalent
- J-35589-A: Brake Pressure Bleeder Adapter
| CAUTION | When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. |
- Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills.
- With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve.
- If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary add Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. Reconnect the brake pipe to the master cylinder port and tighten securely. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. Loosen the same brake pipe to purge air from the open port of the master cylinder. Tighten the brake pipe, then have the assistant slowly release the brake pedal. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened.
- Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm.
- Install the J-35589-A: Brake Pressure Bleeder Adapter to the brake master cylinder reservoir.
- Check the brake fluid level in the J-29532: Diaphragm Pressure Bleeder, or equivalent. Add Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point.
- Connect the J-29532: Diaphragm Pressure Bleeder, or equivalent, to the J-35589-A: Brake Pressure Bleeder Adapter.
- Charge the J-29532: Diaphragm Pressure Bleeder, or equivalent, air tank to 175-205 kPa (25-30 psi).
- Open the J-29532: Diaphragm Pressure Bleeder, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system.
- Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure.
- Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve.
- Install a transparent hose over the end of the bleeder valve.
- Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
- Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve.
- With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit, install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve.
- Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14.
- With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve.
- Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14.
- With the right front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right front hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve.
- Install a transparent hose over the end of the bleeder valve, then repeat steps 13-14.
- After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened.
- Close the J-29532: Diaphragm Pressure Bleeder, or equivalent, fluid tank valve, then disconnect the J-29532: Diaphragm Pressure Bleeder, or equivalent, from the J-35589-A: Brake Pressure Bleeder Adapter.
- Remove the J-35589-A: Brake Pressure Bleeder Adapter from the brake master cylinder reservoir.
- Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
- Slowly depress and release the brake pedal. Observe the feel of the brake pedal.
- If the brake pedal feels spongy perform the following steps: Inspect the brake system for external leaks. Refer to «Brake System External Leak Inspection»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system__brake-system-external-leak-inspection) . Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the brake pressure modulator valve (BPMV). Refer to the following procedures, as appropriate: «Antilock Brake System Automated Bleed»(/cadillac/escalade/gmt900-2006-2014/remont/anti-locktraction-control/#antilock-brake-system-hybrid-hp2-with-electronic-brake-distribution-vehicle-stability-system__antilock-brake-system-automated-bleed) for Two-mode Hybrid vehicles «Antilock Brake System Automated Bleed»(/cadillac/escalade/gmt900-2006-2014/remont/anti-locktraction-control/#antilock-brake-system-non-hybrid-less-than-3900-kg-8600-lb-gvw-with-ebd-vses__antilock-brake-system-automated-bleed) for non-hybrid vehicles less than 3900 kg (8600 lb) GVW «Antilock Brake System Automated Bleed»(/cadillac/escalade/gmt900-2006-2014/remont/anti-locktraction-control/#antilock-brake-system-non-hybrid-greater-thanequal-to-3900-kg-8600-lb-gvw-with-tcs-ves__antilock-brake-system-automated-bleed) for non-hybrid vehicles greater than/equal to 3900 kg (8600 lb) GVW
- Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated.
- If the brake system warning lamp remains illuminated, refer to «Symptoms - Hydraulic Brakes»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system__symptoms-hydraulic-brakes) .
| CAUTION | When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. |
- Inspect the brake fluid for the following conditions, indicating brake fluid contamination: Fluid separation, indicating two types of fluid are present; a substance other than the recommended brake fluid has been introduced into the brake hydraulic system Swirled appearance - oil-based substance Layered appearance - silicone-based substance Fluid discoloration, indicating the presence of moisture or particles that have been introduced into the brake hydraulic system Cloudy appearance - moisture Dark appearance/suspended particles in fluid - dirt, rust, corrosion, brake dust
- Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for swelling, indicating brake fluid contamination.
- If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated by fluid separation and/or a swollen master cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform the following: Remove ALL of the following components listed from the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated as applicable: «Master Cylinder Replacement (JD9)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) «Master Cylinder Replacement (JH6)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) «Master Cylinder Replacement (Two-mode Hybrid)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) «Front Brake Hose Replacement (JH6)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) «Front Brake Hose Replacement (JD9)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) «Rear Brake Hose Replacement (JH6)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) «Rear Brake Hose Replacement (Frame to Rear Axle JH6)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) «Rear Brake Hose Replacement (Frame to Rear Axle JD9)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) «Rear Brake Hose Replacement (JD9)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) «Front Brake Caliper Replacement (2500 Series)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#disc-brake-system__front-brake-caliper-replacement-2500-series) «Front Brake Caliper Replacement (1500 Series)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#disc-brake-system__front-brake-caliper-replacement-1500-series) «Rear Brake Caliper Replacement (2500 Series)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#disc-brake-system__rear-brake-caliper-replacement-2500-series) «Rear Brake Caliper Replacement (1500 Series)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#disc-brake-system__rear-brake-caliper-replacement-1500-series) «Brake Pressure Modulator Valve Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/anti-locktraction-control/#antilock-brake-system-hybrid-hp2-with-electronic-brake-distribution-vehicle-stability-system) Two-mode Hybrid «Brake Pressure Modulator Valve Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/anti-locktraction-control/#antilock-brake-system-non-hybrid-less-than-3900-kg-8600-lb-gvw-with-ebd-vses) Non-Hybrid Less than 3900 kg (8600 lb) GVW «Brake Pressure Modulator Valve Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/anti-locktraction-control/#antilock-brake-system-non-hybrid-greater-thanequal-to-3900-kg-8600-lb-gvw-with-tcs-ves) Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent. Dry the brake pipes using non-lubricated, filtered air. Repair or replace ALL of the following components listed and install them to the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated as applicable: «Master Cylinder Replacement (JD9)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) «Master Cylinder Replacement (JH6)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) «Master Cylinder Replacement (Two-mode Hybrid)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) ; also perform the following: Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and replace if necessary. Refer to «Master Cylinder Reservoir Replacement (Two-mode Hybrid)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) «Master Cylinder Reservoir Replacement (JD9)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) «Master Cylinder Reservoir Replacement (JH6)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) . Replace the brake master cylinder reservoir cap diaphragm. «Front Brake Hose Replacement (JH6)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) «Front Brake Hose Replacement (JD9)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) «Rear Brake Hose Replacement (JH6)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) «Rear Brake Hose Replacement (Frame to Rear Axle JH6)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) «Rear Brake Hose Replacement (Frame to Rear Axle JD9)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) «Rear Brake Hose Replacement (JD9)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) «Front Brake Caliper Overhaul (2500 Series)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#disc-brake-system__front-brake-caliper-overhaul-2500-series) or «Front Brake Caliper Replacement (2500 Series)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#disc-brake-system__front-brake-caliper-replacement-2500-series) «Front Brake Caliper Replacement (1500 Series)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#disc-brake-system__front-brake-caliper-replacement-1500-series) «Rear Brake Caliper Overhaul (2500 Series)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#disc-brake-system__rear-brake-caliper-overhaul-2500-series) or «Rear Brake Caliper Replacement (2500 Series)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#disc-brake-system__rear-brake-caliper-replacement-2500-series) «Rear Brake Caliper Replacement (1500 Series)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#disc-brake-system__rear-brake-caliper-replacement-1500-series) «Brake Pressure Modulator Valve Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/anti-locktraction-control/#antilock-brake-system-hybrid-hp2-with-electronic-brake-distribution-vehicle-stability-system) Two-mode Hybrid «Brake Pressure Modulator Valve Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/anti-locktraction-control/#antilock-brake-system-non-hybrid-less-than-3900-kg-8600-lb-gvw-with-ebd-vses) Non-Hybrid Less than 3900 kg (8600 lb) GVW «Brake Pressure Modulator Valve Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/anti-locktraction-control/#antilock-brake-system-non-hybrid-greater-thanequal-to-3900-kg-8600-lb-gvw-with-tcs-ves) Non-Hybrid Greater than/Equal to 3900 kg (8600 lb) GVW
- If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but WAS contaminated with water or dirt, rust, corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm. The diaphragm may have allowed the moisture or particles to enter the hydraulic system.
- Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11®, GM P/N 12377967 (Canada P/N 992667) or equivalent, DOT-3 brake fluid from a clean, sealed brake fluid container.
- Pressure bleed the hydraulic brake system. Begin the procedure with the pressure bleeder reservoir filled to the maximum-fill level with the correct brake fluid as indicated. Refer to «Hydraulic Brake System Bleeding (Manual)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) or «Hydraulic Brake System Bleeding (Pressure)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) .
- Place the ignition switch in the OFF position.
- Apply and release the brake pedal several times until the brake pedal becomes firm to deplete the power vacuum brake booster vacuum reserve.
- Disconnect the electrical connector and remove the power brake booster vacuum sensor and vacuum hose and position aside.
- Remove the brake master cylinder nuts (1).
- Without disconnecting the brake pipe fittings from the master cylinder, remove the brake master cylinder and support with heavy mechanics wire or equivalent.
- Inspect the O-ring seal on the master cylinder body for damage and replace, if necessary.
- Remove the brake booster pushrod retainer bolt (1).
- Remove the brake booster pushrod retainer (1).
- Disconnect the electrical connector and remove the stoplamp switch (1).
- Disconnect the brake booster pushrod from the brake pedal pin.
- Remove the power vacuum brake booster nuts (1).
- Remove the power vacuum brake booster.
- Remove and discard the power vacuum brake booster gasket.
- Install a new power vacuum brake booster gasket.
- Install the power vacuum brake booster.
- Install the power vacuum brake booster nuts (1) and tighten to 33 N.m (24 lb ft).
- Connect the brake booster pushrod to the brake pedal pin.
- Install the stoplamp switch (1).
- Connect the stoplamp switch electrical connector.
- Install the brake booster pushrod retainer (1).
- Install the brake booster pushrod retainer bolt (1) and tighten to 10 N.m (89 lb in).
- Install the O-ring seal on the master cylinder body, if removed.
- Position the master cylinder to the power vacuum brake booster.
- Install the brake master cylinder nuts (1) and tighten to 33 N.m (24 lb ft).
- Install the power brake booster vacuum sensor and vacuum hose.
- Connect the power brake booster vacuum sensor electrical connector.
- Turn the ignition switch to the OFF position.
- Apply and release the brake pedal several times until the brake pedal becomes firm to depete the power vacuum brake booster vacuum reserve.
- Remove the upper intake manifold sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical/#engine-mechanical-53l-60l-62l-repair-instructions-on-vehicle) .
- Disconnect the electrical connector from the vacuum sensor.
- Remove the vacuum sensor with check valve and hose assembly from the power vacuum brake booster.
- Release the clamp and remove the vacuum brake booster check valve and hose assembly (1).
- Install the vacuum brake booster check valve and hose assembly (1) and secure the clamp.
- Install the vacuum sensor with check valve and hose assembly to the power vacuum brake booster.
- Connect the electrical connector to the vacuum sensor.
- Install the upper intake manifold sight shield. Refer to «Upper Intake Manifold Sight Shield Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical/#engine-mechanical-53l-60l-62l-repair-instructions-on-vehicle) .
- Turn the ignition switch to the OFF position.
- Apply and release the brake pedal several times until the brake pedal becomes firm to delete the power vacuum brake booster vacuum reserve.
- Disconnect the electrical connector from the vacuum sensor.
- Remove the vacuum sensor with check valve and hose assembly from the power vacuum brake booster.
- Release the clamp and remove the vacuum sensor from the vacuum hose.
- Install the vacuum sensor with check valve and hose assembly to the power vacuum brake booster.
- Install the vacuum sensor to the vacuum hose and secure the clamp.
- Connect the electrical connector to the vacuum sensor.
Scheme 15
Scheme 15: Brake Master Cylinder Pressure Sensor Replacement
- Turn the ignition to OFF, without pausing at ACCESSORY, and without applying the brake pedal. Remove the ignition key.
- Wait approximately 1 3 minutes until the brake modulator and HPA pressure relief is complete.
- Disconnect the brake master cylinder (BMC) primary piston position sensor electrical connector.
- Remove the 2 BMC primary piston position sensor screws (1).
- Remove the primary piston position sensor (2). Tilt the rear of the position sensor downward and remove the sensor.
- Install the BMC primary piston position sensor (2).
- Install the 2 primary piston position sensor screws (1) and tighten to 10 N.m (89 lb in).
- Connect the primary piston position sensor electrical connector.
- Inspect the battery state of charge. Refer to «Battery Inspection/Test»(/cadillac/escalade/gmt900-2006-2014/remont/charging-system/#battery-charging-system-and-starting-system) .
- If necessary, connect a battery charger to the 12V battery. Refer to «Battery Charging»(/cadillac/escalade/gmt900-2006-2014/remont/charging-system/#battery-charging-system-and-starting-system) .
- Install a scan tool to the vehicle.
- Turn the ignition ON with the engine OFF.
- Using the scan tool, perform the following steps: Select Diagnostics Select the appropriate vehicle information Select Chassis Select Electronic Brake Control Module (EBCM) Select Module Setup Select BMC Primary Piston Position Relearn and follow the instructions on the scan tool
Power Brake Booster Replacement
| CAUTION | Hydraulic brake systems use two distinct and incompatible fluids. Power steering fluid is used in the hydraulic brake booster system. Brake fluid is used in the master cylinder and brake pipes. Use extreme care when selecting brake system fluids, or seal damage can result. Refer to General Information to select the correct fluid. |
Checking and Adding Fluid
Bleeding the Hydraulic Booster System
Flushing the Hydraulic Booster System
- Apply the park brake and block the wheels.
- Disconnect the inlet hose, the steering gear, and the return hoses from the booster assembly.
- Remove the master cylinder to hydraulic booster nuts and set the master cylinder aside in the engine compartment.
- Remove the stop lamp switch. Refer to «Stop Lamp Switch Replacement (With Adjustable Pedals)»(/cadillac/escalade/gmt900-2006-2014/remont/exterior-lights/#lighting-system) or «Stop Lamp Switch Replacement (Without Adjustable Pedals)»(/cadillac/escalade/gmt900-2006-2014/remont/exterior-lights/#lighting-system) .
- Remove the 4 booster to bulkhead nuts.
- Remove the booster assembly.
- Remove the gasket.
- Install the gasket.
- Install the booster assembly.
- Install the 4 booster to bulkhead nuts and tighten to 33 N.m (24 lb ft).
- Install the stop lamp switch. Refer to «Stop Lamp Switch Replacement (With Adjustable Pedals)»(/cadillac/escalade/gmt900-2006-2014/remont/exterior-lights/#lighting-system) or «Stop Lamp Switch Replacement (Without Adjustable Pedals)»(/cadillac/escalade/gmt900-2006-2014/remont/exterior-lights/#lighting-system) .
- Install the master cylinder to the brake booster and tighten to 33 N.m (24 lb ft).
- Connect the return hose, the steering gear, and the inlet hoses.
- Bleed the hydraulic booster system. Refer to «Power Steering System Bleeding»(/cadillac/escalade/gmt900-2006-2014/remont/electronic-steering/#power-steering-system) .
- Release the park brake and unblock the wheels.
| WARNING | The accumulator contains compressed gas. Always use the proper tools and follow the recommended procedures or personal injury may result. Do not apply heat to accumulator. Do not attempt to repair an inoperative accumulator. Always replace an inoperative accumulator with a new one. Dispose of an inoperative accumulator by drilling a 1.5 mm (1/16 in) diameter hole through the end of the accumulator can, opposite the O-ring. |
| WARNING | Push rod removal is not recommended. Improper staking of the push rod to the Hydroboost reaction piston can result in a loss of brakes. If the rod or seals require service, the entire unit must be replaced. |
- Apply the park brake and block the wheels.
- Depress brake pedal at least 10 times in order to relieve pressure in the accumulator.
- Remove the master cylinder from the hydraulic booster. Refer to «Master Cylinder Replacement (JD9)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) or «Master Cylinder Replacement (JH6)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) or «Master Cylinder Replacement (Two-mode Hybrid)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) .
- Place the J 26889 over the end of the accumulator. See «Special Tools»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) .
- Install the nut on the stud.
- Depress the accumulator with a C-clamp. If the accumulator does not move with moderate pressure, remove the C-clamp and depress the brake pedal ten times in order to relieve pressure in the accumulator.
- Rotate the retaining ring (2) until either end of the ring is under the access hole (1).
- Depress and hold the retaining ring with a small tool inserted into the access hole (1).
- Remove the accumulator retainer ring (1) using a small hook shaped tool.
- Release the C-clamp.
- Remove the nut from the stud.
- Remove the J 26889 . See «Special Tools»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) .
- Remove the accumulator (2) and the O-ring seal (3).
- Lubricate all of the seals and the metal friction points with power steering fluid.
- Install the accumulator (2) and the O-ring seal (3).
- Place the J 26889 over the end of the accumulator. See «Special Tools»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) .
- Install the nut on the stud.
- Depress the accumulator with a C-clamp.
- Install the accumulator retainer ring (1).
- Release the C-clamp.
- Remove the nut from the stud.
- Remove the J 26889 . See «Special Tools»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) .
- Install the master cylinder to the hydraulic booster. Refer to «Master Cylinder Replacement (JD9)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) or «Master Cylinder Replacement (JH6)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) or «Master Cylinder Replacement (Two-mode Hybrid)»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) .
- Release the park brake and unblock the wheels.
| WARNING | The high pressure accumulator (HPA) and the chambers of the brake modulator assembly to which it attaches, store brake fluid at extremely high pressures. Fluid pressure must be relieved before attempting to service the HPA. Ensure that the recommended procedures are followed to relieve system pressure, including using the manual pressure release steps. Failure to properly follow procedures to depressurize the system may result in personal injury. |
- Turn the ignition to OFF, without pausing at ACCESSORY, and remove the ignition key.
- Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(/cadillac/escalade/gmt900-2006-2014/remont/ignition-switchsteering-lock/#general-information__lifting-and-jacking-the-vehicle) .
- Clean any dirt and debris from the brake modulator assembly and the HPA.
- Loosen the manual pressure relief valve (1) 1/4 turn counterclockwise.
- Seat, but do not tighten, the manual pressure relief valve.
- Without disconnecting the brake pipes and hoses, remove the brake pressure modulator assembly bracket. Refer to «Brake Pressure Modulator Valve Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/anti-locktraction-control/#antilock-brake-system-hybrid-hp2-with-electronic-brake-distribution-vehicle-stability-system) .
- Remove the HPA (1).
- Remove and discard the HPA O-ring seal (1).
- Remove any debris from the O-ring seal groove in the brake modulator assembly with a clean, lint-free shop cloth.
- If replacing the HPA, properly render inert and dispose of the HPA. Refer to «Power Brake Booster Pump Fluid Accumulator Disposal»(/cadillac/escalade/gmt900-2006-2014/remont/mechanical-hydraulic/#hydraulic-brake-system) .
- Lubricate a new O-ring seal (1) with Delco Supreme 11®, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
- Install the O-ring seal to the HPA. Ensure the seal is fully seated in the groove of the HPA and is not twisted.
- Install the HPA (1) to the brake modulator assembly. Tighten: Tighten the HPA to 30 N.m (22 lb ft).
- Install the brake modulator assembly bracket and remove the support. Refer to «Brake Pressure Modulator Valve Replacement»(/cadillac/escalade/gmt900-2006-2014/remont/anti-locktraction-control/#antilock-brake-system-hybrid-hp2-with-electronic-brake-distribution-vehicle-stability-system) .
- Tighten the brake modulator manual pressure relief valve (1). Tighten: Tighten the valve to 40 N.m (30 lb ft).
- Perform the «Antilock Brake System Automated Bleed»(/cadillac/escalade/gmt900-2006-2014/remont/anti-locktraction-control/#antilock-brake-system-hybrid-hp2-with-electronic-brake-distribution-vehicle-stability-system__antilock-brake-system-automated-bleed) . Follow the procedure completely to ensure the learn procedure for the pressure and travel sensors has occurred.
Scheme 16
Scheme 16: Power Brake Booster Pump Fluid Accumulator Disposal
System Component Description
The brake assist system consists of the following
System Operation
Brake system input force is multiplied by the brake pedal and transferred by the pedal pushrod to the hydraulic brake master cylinder. Effort required to apply the brake system is reduced by the vacuum brake booster.
Active Brake Booster
Incorporated into the vacuum brake booster, is an electric solenoid actuator. This actuator can be used to apply the brake booster and thus the master cylinder as commanded by the electronic brake control module (EBCM). During stability events, the EBCM can command the solenoid actuator in the brake booster to apply the booster. This quickly provides a large volume of pressurized brake fluid to the brake pressure modulator valve (BPMV). The BPMV will then control the flow of fluid to the brake corners to obtain the appropriate response for the vehicle.
Scheme 17
Scheme 17: Brake Assist System Description and Operation (Hydraulic Assist)
| Callout | Component Name |
| 1 | Master Cylinder |
| 2 | Power Brake Booster Outlet Hose |
| 3 | Power Brake Booster Inlet Pipe/Hose |
| 4 | Hydraulic Brake Booster |
| 5 | Power Steering Gear Inlet Pipe/Hose |
| 6 | Steering Gear |
| 7 | Power Steering Cooler |
| 8 | Power Steering Pump |
The brake assist system consists of the following
The hydraulic brake boost system uses fluid from the power steering pump (8) through the hydraulic boost inlet hose (3) and to the brake booster assembly (4). In addition to supplying the brake system with fluid for increased apply, the power steering pump is also connected to the power steering gear (6) and cooler (7).
The steering pump (8) is a continuous flow device supplying approximately 3 GPM at 1000 RPM, at the pump shaft. The fluid flows through the booster spool valve, then the return hose (5), and then to the steering gear (6). Pressure is produced by applying the brake pedal, resulting in the spool valve being actuated, internal to the hydraulic brake booster. The spool valve produces a marginal restriction that causes pressure in the booster (4) to rise and forces the power piston and therefore the output rod forward to generate force and motion at the master cylinder (1). The brake corners are actuated by the fluid impulse generated by the master cylinder (1). Internal blow by, or pressure relief, is directed to the low pressure return hose (2) back to the power steering pump (8).
Scheme 18
Scheme 18: System Component Description
The hydraulic brake system consists of the following
The brake assist system consists of the following
When the ignition is placed in START or a remote function actuation (RFA) commands remote START, the brake modulator assembly activates and pressurizes brake fluid for use at the wheel apply circuits as needed.
The brake modulator assembly incorporates a motor driven pump which is activated as required to draw brake fluid directly from the master cylinder reservoir, lowering the brake fluid level in the reservoir into the pressurized, or operating, range. The pump pressurizes and delivers the brake fluid to the high pressure accumulator (HPA) to store for use as necessary. Sensor data of HPA fluid pressure is used by the modulator to operate the pump to maintain the pressure of the brake fluid at the HPA within operating range. Working pressure of the HPA stored fluid is 140-180 bar (2030-2610 psi). Peak allowed pressure is 200 bar (2900 psi). Pressure relief is vented back to the master cylinder reservoir.
Brake system mechanical input force from the driver is multiplied by the brake pedal and transferred by the pedal pushrod to the hydraulic brake master cylinder. This mechanical force is converted into hydraulic pressure by the primary piston of the master cylinder. The pressurized brake fluid from the primary piston is delivered to the brake modulator assembly and is directed within the modulator to the brake pedal feel simulator.
To allow operation of the pedal feel simulator, the brake modulator assembly energizes and then closes the normally open (NO) valve to direct brake fluid only to the pedal feel simulator. The brake modulator also energizes and opens a normally closed (NC) valve to allow brake fluid to escape from the backside of the brake pedal feel simulator to the master cylinder reservoir, allowing the simulator piston to move. The pedal feel simulator incorporates a spring which causes increasing brake pedal effort and feedback through the master cylinder, providing brake pedal feel to the driver.
The brake modulator assembly uses sensor data of the brake pedal and pushrod travel and the master cylinder input fluid pressure to determine the amount of braking performance requested by the driver.
Based on the amount of braking action requested by the driver and sensor data inputs of fluid pressure throughout the brake modulator assembly passageways, the modulator uses a boost valve to continuously provide the optimal fluid pressure for use by the wheel apply circuits. The modulator assembly uses the boost valve to both build and relieve pressure within the wheel apply circuits. The boost valve meters the flow of pressurized brake fluid from the HPA to build pressure and relieves pressure as needed by venting fluid through the energized, and open, NC valve to the master cylinder reservoir. The brake modulator assembly also controls various valves in a way similar to a traditional brake modulator, to blend and modulate delivery of brake fluid to the wheel apply circuits, to achieve optimal balance and brake system output performance. The brake modulator delivers brake fluid to the wheel apply circuits as follows
- Through isolation valves directly to the rear wheel apply circuits
- Through isolation valves directly to the secondary pistons of the master cylinder
- The secondary pistons of the master cylinder then delivers pressurized brake fluid directly to the front wheel apply circuits
Pressurized brake fluid is delivered to the wheel apply hydraulic components through the brake pipes and flexible hoses. The wheel apply components then convert the hydraulic pressure back into mechanical force which presses the brake linings against rotating brake system components to slow the vehicle through friction braking.
When the ignition is turned to OFF, without pausing at ACCESSORY, and the brake pedal is not applied, the system will deactivate and depressurize. As the system begins to depressurize, brake fluid will discharge from the HPA and vent back into the master cylinder reservoir. This will cause the brake fluid level in the master cylinder reservoir to rise to the depressurized or system OFF range. The system may take up to 3 minutes to fully depressurize.
If the ignition is turned to ACCESSORY, the system will remain active and pressurized. If the brake pedal is applied before the system has fully depressurized, the brake modulator will maintain the pressure available at the moment of the brake apply until the brake pedal is released. This will increase the amount of time required for the system to depressurize when the ignition is turned to OFF.
The brake modulator assembly also provides a means for manual relief of system pressure through a set-screw. The manual relief of system pressure must be used only if necessary and after the system has powered down.
The brake modulator assembly and the powertrain and hybrid system controllers are in constant communication with each other. Each system is monitoring various system, sensor data, and driver inputs. Working together, a determination is made as to when the most appropriate opportunity for regenerative braking will occur. The brake modulator will request from the powertrain and hybrid controllers the amount of torque braking that is available from the powertrain to be delivered through the primary drive axle. If the powertrain and hybrid controllers in conjunction with the brake modulator have determined to perform a regenerative braking event, the brake modulator will request a specific amount of regenerative or torque braking to be provided from the powertrain.
Simultaneously, the brake modulator continuously evaluates and provides the correct blend of friction braking from the non-primary drive axle, and provides the correct blend of regenerative or torque braking and friction braking from the primary drive axle to provide the most efficient amount of regenerative braking and charging for the needs of the powertrain. All the while, providing optimal braking balance and providing the correct blend and amount of overall vehicle braking action requested by the driver through a brake pedal apply.
Brake system mechanical input force from the driver is multiplied by the brake pedal and transferred by the brake pedal pushrod to the hydraulic brake master cylinder. This mechanical force is converted into hydraulic pressure by the primary piston of the master cylinder.
The pressurized brake fluid from the primary piston is delivered to the brake modulator assembly and is directed within the brake modulator to the wheel apply passageways, rather than to the pedal simulator.
Since the modulator is not energizing the normally open (NO) valve to cause it to close and direct pressurized fluid only to the pedal simulator, the NO valve is open and directing fluid to both the pedal simulator and the wheel apply circuit passageways. To prevent any loss of pressure through the pedal simulator, or through the boost valve, the normally closed (NC) valve is closed since it is not energized by the modulator. Since the NC valve is closed, no fluid can escape from the backside of the simulator, thus preventing any movement of the piston within the pedal simulator and any subsequent loss of pressure. The same is true with the boost valve, since the NC valve is closed, no fluid can escape from the pressure relief side of the boost valve, thus preventing loss of pressure. The pressurized fluid is now delivered through the wheel apply circuit passageways within the modulator as follows
- Through de-energized, open isolation valves directly to the rear wheel apply circuits
- Through de-energized, open isolation valves directly to the secondary pistons of the master cylinder
- The secondary pistons of the master cylinder then deliver pressurized brake fluid directly to the front wheel apply circuits
If a hydraulic failure occurs in the boost circuit of the modulator during further pedal apply, the system will operate as follows
The mechanical input force is applied further as the primary piston of the master cylinder directly contacts the secondary pistons, which then convert the mechanical force into hydraulic pressure. The pressurized brake fluid from the secondary pistons is delivered directly to the front wheel apply circuits.
Brake Warning Indicator
The instrument panel cluster (IPC) illuminates the Red Brake Warning indicator when one or more of the following occurs.
- The body control module (BCM) detects that the park brake is engaged.
- The IPC detects a low brake fluid condition. The IPC receives a low brake fluid signal from the low brake fluid switch in the master cylinder reservoir requesting illumination.
- The electronic brake control module (EBCM) detects an ABS malfunction which disables dynamic rear proportioning (DRP). The IPC receives a serial data message from the EBCM requesting illumination.
- The IPC performs the bulb check at the start of each ignition cycle. The Red Brake Warning indicator illuminates for approximately 3 seconds before turning OFF.
- The IPC detects a loss of serial data communications with the EBCM.
The hydraulic brake system consists of the following
Mechanical force is converted into hydraulic pressure by the master cylinder, regulated to meet braking system demands by the pressure balance control system, and delivered to the hydraulic brake wheel circuits by the pipes and flexible hoses. The wheel apply components then convert the hydraulic pressure back into mechanical force which presses linings against rotating brake system components.
Illustrations Tool Number/Description J 26889 Accumulator Piston Compressor J 28662 Brake Pedal Effort Gauge J 29532 Diaphragm Pressure Bleeder J 35589-A Brake Pressure Bleeder Adapter J 45405 Brake Pipe Flaring Tool
Scheme 19
Scheme 20
Scheme 21
Scheme 22