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Brake Pedal Excessive Travel

  1. Were you sent here from Hydraulic Brake Symptom Table? If so, go to next step. If not, see DIAGNOSTIC STARTING POINT - HYDRAULIC BRAKE  under TROUBLE SHOOTING.
  2. Inspect for proper brake pedal travel. See BRAKE PEDAL TRAVEL MEASUREMENT & INSPECTION  under ADJUSTMENTS & INSPECTIONS. Is the brake pedal travel distance within the acceptable level? If so, go to step  5 . If not, go to next step.
  3. Inspect for worn, missing, misaligned, bent or damaged brake pedal system components.
    • For the brake pedal pushrod component inspection, see BRAKE PEDAL PUSHROD INSPECTION  under ADJUSTMENTS & INSPECTIONS.
    • Inspect the brake pedal bushings for excessive wear and/or damage and inspect the brake pedal for a bent and/or damaged condition.
    Replace the brake pedal system components that are worn, missing, misaligned, bent or damaged, refer to the following procedure(s) as necessary. Did you find and replace any worn, missing, misaligned, bent or damaged brake pedal system components? If so, go to next step. If not, go to step . 5
  4. Reinspect for proper brake pedal travel. See BRAKE PEDAL TRAVEL MEASUREMENT & INSPECTION  under ADJUSTMENTS & INSPECTIONS. Is the brake pedal travel distance within the acceptable level? If so, go to step  9 . If not, go to next step.
  5. Inspect the hydraulic brake system for proper operation. See HYDRAULIC BRAKE SYSTEM TESTING  under SYSTEM TESTING. Did you find and correct a condition? If so, go to step  9 . If not, go to next step.
  6. Inspect the drum brake system for proper operation. See DRUM BRAKE SYSTEM TESTING  under SYSTEM TESTING. Did you find and correct a condition? If so, go to step  9 . If not, go to next step.
  7. Inspect the disc brake system for proper operation. See DISC BRAKE SYSTEM TESTING  under SYSTEM TESTING. Did you find and correct a condition? If so, go to step  9 . If not, go to next step.
  8. Inspect the brake assist system for proper operation. See BRAKE ASSIST SYSTEM TESTING  under SYSTEM TESTING. Did you find and correct a condition? If so, go to next step. If not, go to DIAGNOSTIC STARTING POINT - HYDRAULIC BRAKE  under TROUBLE SHOOTING.
  9. Road test the vehicle to confirm proper operation. Is the condition still present? If so, go to step  2 . If not, system is okay.
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