Hydro-Max™ Hydraulic Brake Booster and Master Cylinder
Contents
1. SWITCH 1 BATTERY STOP LIGHT T Figure 7 Schematic of Electronic Monitor Module Type I Hydro Max Technical Manual 9 BOSCH Pin Functions Pin 1 Function a Provides path to flow switch to ground for pin 2 to allow test of red light during vehicle start up b Suppresses negative voltage transients into pin 5 from the relay coil Provides path to pin 1 to flow switch to vehicle ground to allow test of red light during vehicle start up Note Pin and2 are connected with a diode in between With the key in the on position the red dash panel light should illuminate anytime hydraulic flow from the fluid power source drops to a range of 0 5 to 1 1 gpm The range at which flow switch continuity occurs Open circuit when all is okay but switches to ground pin 4 during vehicle start or during a detected fault Connection to ground turns on warning light and buzzer Connects monitor module to vehicle ground Supplies power from module to amber light buzzer and relay coil Current flow through this terminal must be limited to 300 mA a Monitors for voltage to backup pump during startup If none detected pin 3 remains grounded connected to pin 4 b Monitors for continuity through the backup pump to vehicle ground during vehicle operation engine on Pin 3 switches to ground pin 4 if continuity is lost Brings power into module from ignition switch Brings powe2. sse eene 9 Application Information esses eene eee 13 Hydrouh eeu 13 Brake Fluid Tubing Hoses and Fittings 13 Booster Fluid Tubing Hoses Fittings sss 14 Booster Fluid Source eene 15 Installation Recommendations esee 16 Pedal Return Springs essere 17 Pedal Stop and Proper Spring Load seem 18 TOU DIC SMO EE 19 Printed in the United States of America Hydro Max Technical Manual 2002 Robert Bosch Corp All rights reserved BOSCH General Description The is a hydraulically powered brake booster which provides power assist for applying hydraulic brakes A booster combined with a master cylinder refer to Figure 1 forms the hydraulic brake actuation unit A typical assembly is shown in Figure 1 The booster reduces the pedal effort required to apply the brakes as compared to a non power system BRAKE FLUID RESERVOIR FLOW SWITCH INLET PORT ex MASTER CYLINDER SECONDARY OUTLET PORT DIFFERENTIAL PRESSURE SWITCH BACKUP PUMP FLUID LEVEL INDICATOR SWITCH PRIMARY OUTLET PORT Figure 1 Hydro Max Booster and Master Cylinder Assembly Hydro Max Booster The hydraulic booster is comprised of an open center valve and reaction feedback mechanism a power piston a 12 and 24 volt backup pump and an integral flow switch It is powered by either the power steering pump or other
3. Pedal Stop and Proper Spring Load The pedal stop must be adjusted such that when the brake pedal is fully released there is no load on the grommet that retains the pedal rod to the Hydro Max booster When the brake pedal is fully released the spring load must not be greater than that required to support the pedal weight The reason for a properly adjusted pedal stop and for the limitation on spring load is to prevent the spring from pulling on the grommet within the Hydro Max booster and damaging the grommet The grommet is not designed to be loaded in this manner Any adjustment of the brake switch and backup pump must not compromise the adjustment of the pedal stop ACAUTION It is a commmon practice to stack vehicles on top of each other to deliver the vehicles An air cylinder is typically used to apply the brake pedals in the towed vehicles When installing such a cylinder be sure that the backup pump turns off when the towing vehicle brake pedal is released Hydro Max Technical Manual 18 BOSCH Condition Hard Pedal Excessive pedal travel pedal goes to the floor TROUBLE SHOOTING Binding pedal linkage Pedal misaligment side to side Low booster supply flow Power steering pump flow control valve Power steering pump relief valve setting too low Fluid contamination Master cylinder Booster Tube and hose passages are blocked shut Improper pedal adjustment Contact dealer for ser
4. BOSCH J8jsejy pue 5 xeW O1pAH 4 dNNd 30 3H 5 NYNLAY 1514 83M Od LAVHS LNdLNO NOLSId H3MOd SNI4HdS NYNLAY SA TVA NOLSId H3MOd 3ATVA 3 1 OSH L Nid NOLLOVSH NOLSId NOLLOV3M LAWWOYS TRE i dow 5 HOLV 1N 9348 AYNSSAYd 555555355 13VHS NOLSId E Ney SNIHSf8 SIVAS LAVHS LN NI MO SHO SNIMH O LVAS SAA IVA MO3HO LAIN lHOd 131100 Se 85010 ASSY 5 Nad 0 ASSY HOLIMS 5 MO TJ NOLSId HOLIMS A SSY HOLIMS Hydro Max Technical Manual BOSCH Master Cylinder In the released position refer to Figure 5 actuators of both the primary and secondary pistons are in with their respective compensating valve stems which project into the cylinder bore This contact tilts the valves to an open position which allows hydraulic fluid in the reservoir sections to communicate with the primary and secondary pressure chambers Each pressure chamber has a piston actuator subassembly containing a preloaded caged spring and return spring Initial forward travel of the primary piston moves the primary actuator away from its compensating valve permitting the valve to seat Closure of this valve shuts off the passage between the primary pressure chamber and the reservoir sec
5. hydraulic source The backup pump provides a secondary power source for the hydraulic booster and is controlled by the integral flow switch Master Cylinder The master cylinder is a split system type with separate fluid chambers pistons and outlet ports for the front and rear brake circuits A differential pressure switch fluid level indicator switch and remote reservoir are also available A typical Hydro Max booster and master cylinder assembly installation in a hydraulic braking system is shown in Figure 2 Hydro Max Technical Manual BOSCH 5 Buryejg e Ajquiassy 134se pue jedIdAL z eunBi4 LINN 587 sayvud LNO 43 OL sayvud OL sayvud LNO J OL 9NIS331S 7 De NOILINSI OL YOLINOW annoys lt 922 9 9NINNVM OL 1H917 OL Hydro Max Technical Manual BOSCH Principle of Operation Hydro Max Booster During normal system operation refer to Figure 4 fluid flow from a hydraulic power source usually the power steering pump enters the inlet port of the Hydro Max booster flows through the power piston around the throttle valve and through the flow switch exiting through the outlet port Force applied to the brake pedal by the vehicle operator is multiplied by the lever ratio of the pedal mechanism to move the pedal rod of the booster This mo
6. of 100 F The 24 volt backup pump can have a steady state maximum draw of 27 5 amps at 100 F Relay An optional relay is available for attachment to the booster The relay connects to a sealed and mechanically latched wiring connector The function of the relay is to provide current to the backup pump when triggered by the flow switch Flow Switch The function of the flow switch is to activate the relay when normal hydraulic power source fluid flow is interrupted turning on the backup pump The flow switch has two terminals A and B Ais positive B is connected to the booster housing and can be used as an optional harness ground The flow switch itself 1s grounded through the booster housing A sealed and mechanically latched connector connects the flow switch to the backup pump relay circuitry Differential Pressure Switch The differential pressure switch reacts to a loss of master cylinder hydraulic pressure in either side of the split hydraulic system and can illuminate a warning light at the instrument panel When pressure is lost in either the primary or secondary circuit of the master cylinder the switch closes The electrical switch will remain closed until the malfunction is corrected When both systems develop normal pressure the switch will return to center and open the electrical switch circuit A mechanically latched connector is attached to the switch The switch has two tabs on a common terminal positive and is gro
7. D SINGLE EYE CLEVIS Figure 12 Basic Pedal Rod Designs Hydro Max Technical Manual 16 BOSCH ATTENTION Regardless of mounting location the following requirements must be followed Mount the unit such that the pedal rod throughout full pedal travel does not articulate more than plus or minus 5 above or below booster centerline The brake pedal lever must be aligned side to side with the booster centerline to prevent linkage binding The brake pedal and mechanical linkage must provide enough travel to fully stroke both booster and master cylinder i e the brake pedal must not bottom on the floor of the vehicle A pedal ratio of between 2 8 1and 3 3 1 is recommended to provide the desired pedal feel The Hydro Max booster and master cylinder assembly must be mounted horizontally The reservoir of the master cylinder must be upright The backup pump must always be at the bottom of the booster The unit must be protected from environmental and fluid temperatures over 2509F General Safety Note Unique usage or applications of the Hydro Max booster and master cylinder assembly requires input from Bosch and validation by the vehicle manufacturer Pedal Return Springs Any vehicle application utilizing a Hydro Max booster and a brake pedal return spring must have 1 A properly adjusted pedal stop 2 A limited spring load at the pedal released position Hydro Max Technical Manual 17 BOSCH
8. Hydro Max Hydraulic Brake Booster and Master Cylinder Technical Manual BOSCH BOSCH Important Service Notes The information in this publication was current at the time of printing The information presented in this publication is subject to change without notice or liability The information contained in this publication is intended for use by properly trained and equipped professional technicians It is NOT for the Do It Yourselfer Failure to follow safety and repair procedures can result in personal injury or damage to vehicles components and equipment Correspondence concerning this manual should be addressed to Robert Bosch LLC Attn Medium Truck Brake Engineering 3737 Red Arrow Highway St Joseph Michigan 49085 This manual can be viewed or downloaded at http www bosch us Fax 269 428 6704 August 2003 Hydro Max Technical Manual BOSCH Table of Contents General ote ce a re 1 1 Master od se teet reete E 1 Principle ODer tiona iacebat eati eer 3 Hydro Max 3 Maste GY INC nee 5 Electrical Operating System sese 7 Basic Operation of Booster and Master 8 Electronic Monitor Module
9. NI Hd NOI193S 10 4353 4 AYYNI ASSY HOLIMS MHIOAH3S3H HLIM 1 014 WNovaHdvia MIOAH3S3H 010114 035 MHIOAH3S3H AHVONOO3S Hydro Max Technical Manual BOSCH Electrical Operating Systems FLUID LEVEL INDICATOR SWITCH FLOW SWITCH HARNESS GROUND OPTIONAL 3 FLOW SWITCH s NEM PRESSURE SWITCH O GN LA BACKUP PUMP CHASSIS GROUND Figure 6 Schematic of Electrical Operating System Hydro Max Technical Manual 7 BOSCH Basic Operation of Hydro Max Booster Assembly and Master Cylinder Reference Figure 6 for the following electrical components of the booster and master cylinder Backup Pump The Hydro Max hydraulic booster has a backup pump which will provide hydraulic boost at a reduced rate if the normal source of fluid is interrupted refer to Figure 3 The signal for operation of the backup pump comes from the flow switch If normal flow is interrupted the flow switch will close and activate the relay which will turn on the backup pump The backup pump is available for 12 and 24 volt systems The 12 volt backup pump can draw a steady state maximum of 55 amps at a power steering fluid temperature
10. flush and refill with the recommended fluid See vehicle service manual if brakes are adjustable Bleed brake system Drain the system flush and refill with recommended fluid Replace defective hoses Contact dealer for service Hydro Max Technical Manual 20 BOSCH Actuated pedal does not return continued Pulsating brake pedal Brake self apply Dragging brake TROUBLE SHOOTING Fluid contamination Master cylinder Binding booster Self applied booster fluid flow too high ABS operation Wheel bearings loose or worn Excessive rotor hickness variation Parking brake control valve HR1 has internal leak Self applied booster fluid flow too high Constricted master cylinder reservoir vent Self applied booster fluid flow too high See vehicle service manual for type of fluid required Drain flush and refill system replace booster or master cylinder as appropriate and power steering reservoir filter as necessary Replace master cylinder Replace booster Repair or replace power steering pump See appropriate service manual See appropriate service manual See appropriate service manual See appropriate service manual Repair or replace power steering pump Clean vent passage in reservoir cap Repair or replace power steering pump Hydro Max Technical Manual 21 BOSCH Condition Dragging brake continued Noise Whistle Backup pump opera
11. hydraulic fluids They must not be mixed Using the incorrect fluid will permanently damage the seals and can cause the brakes to malfunction Brake Fluid Tubing Hoses and Fittings Brake fluid lines tubing and flexible hose transmit fluid under pressure between the master cylinder and the brakes The hoses are the flexible links between wheels or axles and the frame or body The hoses must withstand fluid pressure with minimal expansion and must be free to flex without damage during normal suspension deflection and wheel turns The following SAE specifications or their successors if appropriate are recommended for consideration as a minimum requirement when outfitting a vehicle with brake fluid tubing hoses and fittings The hoses should conform to SAE J1401 Hydraulic Brake Hose Automotive The tubing should conform to SAE J1047 Tubing Motor Vehicle Hydraulic Brake System The fittings should conform to SAE J516a Hydraulic Hose Fittings or SAE J512 Automotive Tube Fittings Contact the vehicle manufacturer for specific requirements for individual applications Hydro Max Technical Manual 13 BOSCH Booster Fluid Tubing Hoses and Fittings The pressure line that supplies fluid to the booster must be a 1 2 diameter flexible or rigid pressure line conforming to SAE J188 and typically designed to run from the steering gear to the Hydro inlet The Hydro Max inlet port utilizes a tube arrangement as shown in Figu
12. linder reservoir A low fluid level can result from brake shoe lining wear or it can occur if there is an external leak in the vehicle brake system A differential pressure switch is available It illuminates a light on the dash panel to warn when there is a pressure differential between the primary and secondary brake circuits caused by a leak in one circuit This may occur when one circuit leaks or is improperly bled A remote reservoir application is available where under the hood space constraints prohibit the use of a conventional booster and master cylinder assembly In a remote application the master cylinder reservoir is mounted separately from the master cylinder Hydro Max Technical Manual 5 BOSCH Jepun 9 sayseyw 180 HOLIMS 553 TVIIN343441IQ0 1VN93INI 39vds 343315 anid 10045 01514 0 0235 1v3S 38nl A18N3SSV HOLIMS 9NINHdS 438AVHO 3Mf SS 34d 1804 131100 1903 131100 AMVONOO3S ASSV 8nS YOLVNLOV 7 3A1VA 9NILVSN3dWOO 0 0035 9NI3dS ASHVONOO3S 145534 Wen Ny 11 C1VNOI1dO ASSV 8nS YOLVNLOV HOLIMS YOLVOIOGNI NOISId Hd 13431 01013 INJA 9 3015 NOISId AMNVONOO3S SNIIVSN3dAWOO AYY
13. r input to monitor module from ignition switch or Hydro Max brake pedal switch 1 Monitors for voltage to backup pump during vehicle startup If none detected pin C remains grounded connected to pin D 2 Monitors for continuity through backup pump to vehicle ground during vehicle operation engine on Pin C switches to ground pin D if continuity is lost Monitors output of the backup pump switch that turns on the backup pump to allow comparison with pin If different for gt 1455 seconds then pin C switches to ground pin D and latches Monitors output of stop light switch to allow comparison with pin G If different for gt 14 5 seconds then pin C switches to ground pin D and latches Not used Not used Hydro Max Technical Manual 12 BOSCH Application Information Hydraulic Fluids The Hydro Max booster uses power steering fluid as the medium of transmitting power The master cylinder uses DOT 3 brake fluid per SAE J1703 unless otherwise specified on the top of the reservoir Service maintenance of motor vehicle brake fluid in motor vehicle brake actuating systems is covered in SAE J1707 information report ACAUTION Before using any other type of fluid in the booster or in the master cylinder contact the Bosch Hydraulic Actaution and Truck Brake Engineering Department See inside of front cover ACAUTION The booster and the master cylinder use two 2 distinctly different incompatible
14. r into module from brake switch Only needed when ignition switch is off Enables backup pump to operate when ignition is off Hydro Max Technical Manual 10 BOSCH Monitor Module ll 12 voit oniy Features 1 Performs start up self test for proper electrical signal to backup pump 2 Continuously tests for an open circuit in backup pump 3 Tests for voltage during brake application in brake light circuit and backup pump relay coil circuit on vehicles equipped with dual brake switches 4 Turns on warning light s and buzzer if any of the above tests indicate a backup pump system electrical malfunction The warnings are continuous until the malfunction is corrected or the power is shut off 5 Absence or malfunction of the module will not affect backup system operation 6 Turns on light s and buzzer when integral differential pressure switch is activated FLOW SWITCH T DIFFERENTIAL PRESSURE FO SWITCH RED LIGHT BATTERY STOP LIGHTS Figure 8 Schematic of Electronic Monitor Module Type Il Hydro Max Technical Manual 11 BOSCH Pin Functions Pin gt Function Suppresses negative voltage transients into pin E from the relay coil Not used Open circuit when all is okay but switches to ground pin D during vehicle startup or during a detected fault Connection to ground switches on warning light and buzzer Connects monitor module to vehicle ground Powe
15. rain flush and refill system replace booster or master cylinder as appropriate and power steering reservoir filter as necessary Replace seals Replace o ring See vehicle service manual tighten and replace if necessary None Does not affect operation Hydro Max Technical Manual 23 BOSCH Fluid level indicator light comes on Brake indicator light and buzzer malfunction TROUBLE SHOOTING Low fluid level Fluid level indicator switch Brake pads worn out Vehicle specific Inspect brake pads replace as necessary add fluid as required Replace master cylinder Inspect brake pads replace as necessary add fluid as required See vehicle service manual Hydro Max Technical Manual 24 Correspondence concerning this manual should be addressed to Robert Bosch LLC Medium Truck Brake Engineering 3737 Red Arrow Highway St Joseph Michigan 49085 Fax 269 428 6704 Printed in the United States of America Copyright O 2002 Robert Bosch Corporation
16. re 9 not supplied by Bosch For tube flare configuration see Figure 10 8 7 TUBE AND NUT ASSEMBLY MINIMUM 2771464 TIGHTEN TO 22 34 Nm NOT SUPPLIED THREAD O RING 2772007 BY BOSCH 11 68 0 25 CHECK VALVE SEAT amp O RING CHECK BALL 22 7340 63 0725 0075 5355 015 145x 005 D 644 010 8 4595 0025 o OG 495 005 R 015 005 025 005 Figure 10 Tube Flare Configuration The return line must be a 1 2 diameter hydraulic hose attached to the Hydro Max outlet port See Figure 11 The return line and clamp must be selected so that it will withstand worst case vehicle operating conditions such as back pressures resulting from start up at extremely cold temperatures or from devices installed down stream of the booster Hydro Max Technical Manual 14 BOSCH 814 27 28 38mm Figure 11 Outlet Port Booster Fluid Source The booster is designed to perform in a flow range of 3 2 to 5 0 gpm Flow rate through the booster can impact vehicle stopping distance therefore the vehicle manufacturer must determine the required minimum flow rate Flow rates below 3 2 gpm can cause slower response times when the booster is applied Flow rates higher than 5 0 gpm may contribute to the booster self applying which will cause brake drag or fluid overheating The fluid power source must be capable of supplying 1 000 psi to the boo
17. ster plus any additional pressure required by other devices in the system such as a power steering gear If a power steering gear is used the steering gear must be balanced so that it can handle the pressures generated in the steering gear return line It must also have an internal relief valve setting lower than the pump relief to allow the steering gear to relieve before the hydraulic pump does It must also have an internal by pass to allow manual steering during booster backup system operation The manufacturer must adhere to the flow path illustrated in Figure 2 Hydro Max Technical Manual 15 BOSCH Installation Recommendations The Hydro Max booster is generally mounted to a vehicle s dash panel If necessary the Hydro booster and master cylinder may be mounted remotely from the vehicle dash panel and actuated by appropriate linkage Four mounting holes are provided in the booster housing through which up to four studs can be pressed Use of Grade 5 3 8 16 or M10 locknuts having self contained prevailing torque features that are frictionally resistant to rotation are recommended See Figure 12 for the three basic pedal rod designs offered The threaded pedal rod screws into the customer supplied attachment to the brake pedal The pin that attaches the pedal rod to the brake pedal must insert freely The attachment mechanism of the pedal rod should be of sufficient strength to prevent linkage binding THREADE
18. tes continuously TROUBLE SHOOTING Stuck or bound caliper pins or rails Binding booster Binding pedal linkage Master cylinder Soft or swollen master cylinder seals due to brake fluid contamination Tube and hose passages restricted Inherent in some boost ers whistle Brake switch Monitor module Relay Flow switch Binding pedal linkage See appropriate service manual Replace booster Contact dealer for service Replace master cylinder Flush out old brake fluid then replace master cylinder and add new brake fluid Replace the parts containing the restriction None Does not affect operation See vehicle service manual See vehicle service manual See vehicle service manual Remove switch components clean inspect for damage or contamination and replace if necessary Contact dealer for service Hydro Max Technical Manual 22 BOSCH TROUBLE SHOOTING Condition Backup pump Same as above does not operate Electrical ground Backup pump Leakage Master cylinder Booster Master cylinder reservoir vent caps Fluid contamination Backup pump mounting seals Flow switch seal Hydraulic fittings and connections Silicone floating This material is an assembly in master cylinder lubricant Repeat as above See service manual Replace backup pump Replace master cylinder Replace booster Replace diaphragms and caps See vehicle service manual for type of fluid required D
19. tion serving the primary chamber Further movement of the primary piston creates pressure in the primary pressure chamber causing the secondary piston and actuator to move As the secondary piston and actuator move the secondary compen sating valve closes shutting off the passage between the secondary pressure chamber and the reservoir section serving the secondary chamber Additional movement of the primary piston causes both chambers to build pressure When the load on the primary piston is removed fluid pressure in each chamber combined with return spring force causes the primary and secondary pistons to return to their initial released positions Each actuator opens its respective compensating valve reopening the passage between the individual reservoir sections and its associated pressure chamber Should the rate of release be great enough to cause a partial vacuum in the chamber the compensating valve will open to allow replenishment of fluid into the cylinder bore Any excess fluid remaining at the end of the stroke due to pumping and or volume change due to tempera ture fluctuation is released to the reservoir as the compensating valves open The primary circuit is separated from the secondary hydraulic circuit Hydraulic leakage in one circuit does not affect the function of the other circuit A fluid level indicator switch is available It illuminates a light on the dash panel to warn of low brake fluid level in the master cy
20. unded through the master cylinder Fluid Level Switch When the fluid reaches a predetermined level low fluid level the switch closes and can illuminate a warning light at the instrument panel A sealed and mechanically latched connector is attached The switch has two terminals positive and negative which are interchangeable Chassis Ground The booster and master cylinder assembly must be provided with a ground path that will carry the maximum current of the backup pump Hydro Max Technical Manual BOSCH MEM Electronic Monitor Modules 2 oniy Bosch recommends that a monitor module be included to monitor the electrical integrity of the backup system Bosch offers two types with the following features and functions Monitor Module Type Features 1 Performs start up self test for proper electrical signal to reserve backup pump 2 Continuously test for an open circuit in backup pump 3 Turns on vehicle warning light and buzzer if any of the above tests indicate a backup system electrical malfunction The warnings are continuous until the malfunction is corrected or the power is shut off 4 Conveys signal to provide electrical power to the backup pump via the relay 5 Provides a centralized housing for diodes 6 Includes an integral differential pressure switch light check at start up DIFFERENTAL PRESSURE SWITCH BACKUP PUMP ut np o o o
21. vement closes the throttle valve which restricts flow This restriction of flow which results in a pressure increase acting on the power piston applies an amplified force to the master cylinder primary piston A reaction piston inside the power piston subassembly provides the driver pedal feel during an application of the brake pedal Fluid flow through the flow switch opens the backup pump electrical circuit during normal operation A separate check valve in the backup pump prevents back flow through the pump during normal power applications In the event normal flow from the power source is interrupted the backup pump provides the power at a reduced rate for stopping See Figure 3 for performance curve Upon flow interruption the integral flow switch closes energizing a relay providing electrical power to the backup pump During backup operation the pump re circulates fluid within the booster assembly with pressure built on demand via the throttle valve Fluid is retained within the booster by the inlet port check valve Figure 3 illustrates the typical relationship of master cylinder pressure and input force of the booster 2 BORE MASTER CYLINDER OUTPUT PRESSURE PSI 32 120 200 300 400 500 600 BOOSTER INPUT FORCE POUNDS Figure3 Typical Performance Curve Hydro Max Technical Manual 3
22. vice Contact dealer for service Repair replace power steering pump check tension in belt Repair replace power steering pump check tension in belt Replace power steering pump See vehicle service manual for type of fluid required Drain flush and refill system replace booster or master cylinder as appropriate and power steering reservoir filter as necessary Replace master cylinder Replace booster Replace parts containing blocked passages See vehicle service manual for pedal rod adjustment if system 15 adjustable Hydro Max Technical Manual 19 BOSCH Condition Excessive pedal travel pedal goes to the floor continued Pulsating brake pedal Soft spongy brakes Actuated pedal does not return TROUBLE SHOOTING External leak in brake fluid system Internal master cylinder leak Air in brake fluid system Brake linings Master cylinder Weak brake hoses that expand under pressure Poor quality brake fluid low boil point Brake self adjusting mechanism Air in hydraulic brake system Poor quality brake fluid low boil point Weak brake hoses that expand under pressure Binding pedal linkage Check all fittings and connections for the master cylinder calipers hoses and tubes replace if necessary Replace master cylinder Bleed system Inspect and adjust or replace brake shoes if necessary Replace master cylinder Replace hoses Drain the system
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