Hydraulic Brake Flushing
Hydraulic Brake System Flushing
Warning: Refer to Brake Fluid Warning (Dangers, Warnings, and Cautions).
Warning: Refer to Brake Fluid Irritant Warning (Brake Fluid Irritant Warning).
Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution (Vehicle Damage Warnings).
Caution: Refer to Filling the Master Cylinder Caution (Filling the Master Cylinder Caution).
1. 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
2. Inspect the master cylinder reservoir cap (1) and the reservoir-to-master cylinder grommets (5) for swelling, indicating brake fluid contamination.
3. 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 and/or swollen reservoir-to-master cylinder grommets, perform the following:
1. Remove ALL of the components containing internal rubber seals or linings which have been contaminated by the contaminated brake fluid. Refer to the following procedures:
* Master Cylinder Replacement (1.8L Engine) (Master Cylinder Replacement)Master Cylinder Replacement (2.4L Engine) (Master Cylinder Replacement)
* Front Brake Hose Replacement (Front Brake Hose Replacement)
* Rear Brake Hose Replacement (All Wheel Drive and GT) (Rear Brake Hose Replacement)Rear Brake Hose Replacement (Except All Wheel Drive and GT) (Rear Brake Hose Replacement)
* Front Brake Caliper Replacement (Front Brake Caliper Replacement)
* Rear Brake Caliper Replacement (All Wheel Drive and GT) (Rear Brake Caliper Replacement)Rear Brake Caliper Replacement (Except All Wheel Drive and GT) (Rear Brake Caliper Replacement)
* Brake Pressure Modulator Valve Replacement (Service and Repair)
2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent.
3. Dry the brake pipes using non-lubricated, filtered air.
4. Clean the brake master cylinder reservoir using denatured alcohol, or equivalent. Refer to Master Cylinder Reservoir Replacement (Master Cylinder Reservoir Replacement).
5. Dry the reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and replace if necessary.
6. Replace the brake master cylinder reservoir cap.
7. Repair or replace the master cylinder. Refer to Master Cylinder Replacement (1.8L Engine) (Master Cylinder Replacement)Master Cylinder Replacement (2.4L Engine) (Master Cylinder Replacement).
8. Repair or replace ALL of the following components listed and install them to the vehicle. Refer to the following procedures:
* Front Brake Hose Replacement (Front Brake Hose Replacement)
* Rear Brake Hose Replacement (All Wheel Drive and GT) (Rear Brake Hose Replacement)Rear Brake Hose Replacement (Except All Wheel Drive and GT) (Rear Brake Hose Replacement)
* Front Brake Caliper Overhaul (Front Brake Caliper Overhaul)or Front Brake Caliper Replacement (Front Brake Caliper Replacement)
* Rear Brake Caliper Overhaul (All Wheel Drive and GT) (Rear Brake Caliper Overhaul)Rear Brake Caliper Overhaul (Except All Wheel Drive and GT) (Rear Brake Caliper Overhaul)or Rear Brake Caliper Replacement (All Wheel Drive and GT) (Rear Brake Caliper Replacement)Rear Brake Caliper Replacement (Except All Wheel Drive and GT) (Rear Brake Caliper Replacement)
* Brake Pressure Modulator Valve Replacement (Service and Repair)
4. 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 which may have allowed the moisture or particles to enter the hydraulic system.
5. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R) (GM P/N 12377967) or the equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
6. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Service and Repair).