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Brake Pedal Travel Inspection

NOTE: Brake pedal travel is not adjustable. Use following procedure to determine if brake pedal travel is as specified.
NOTE: Required Tools: Brake Pedal Effort Gauge (J-28662).
  1. Most low brake pedal or excessive pedal travel problems are caused by air in hydraulic system. Bleed hydraulic system before continuing procedure. See BLEEDING BRAKE SYSTEM  . Other possible causes of excessive pedal travel are parking brake adjustment, excessively worn linings, or leak in hydraulic system.
  2. 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 Brake Pedal Effort Gauge to the brake pedal.
  3. Measure and record the distance from the brake pedal to the rim of the steering wheel; note the points of measurement.
  4. Apply and maintain the brakes with 100 lbs (445 N) of force to the brake pedal, as indicated on the Brake Pedal Effort Gauge. While maintaining 100 lbs (445 N) of force to the brake pedal, measure and record the distance from the same point on the brake pedal to the same point on the rim of the steering wheel.
  5. Release the brakes and repeat step  4 to obtain a second measurement.
  6. Average the first and second measurements recorded during the 2 applies of the brakes. Subtract the initial measurement, unapplied, from the averaged, applied measurement to obtain the brake pedal travel distance. Maximum brake pedal travel should be (measured with the ignition OFF, brake booster power assist depleted, and the brakes cool): 2.91 in. (74 mm).
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