Pinpoint Test O: Excessive/Erratic Brake Pedal Travel

O1: TEST ON ROUGH ROAD
1. Road test the vehicle on rough road conditions
2. Apply the brakes slowly
  Is the brake pedal effort and brake pedal travel normal?
  
  Yes
  
  No action required, vehicle is OK
  
  No
  
  GO to O2.
O2: CHECK BRAKE FLUID LEVEL
1. Check the brake master cylinder reservoir fluid level
  Is the fluid level OK?
  
  Yes
  
  GO to O3.
  
  No
  
  Check brake master cylinder reservoir sealing points. For additional information, refer to Brake master cylinder component test in this article. Add brake fluid and bleed the brake system. Re-test the system for normal operation
O3: CHECK BRAKE PEDAL RESERVE
1. Run engine at idle speed
2. Apply the brake pedal lightly three or four times
3. Wait 15 seconds for the vacuum to replenish
4. Push down on the brake pedal until it stops moving downward or an increased resistance to the brake pedal travel occurs
5. Hold the brake pedal in the applied position while increasing the engine speed to 2000 revs/min
6. Release the accelerator pedal
  Does the brake pedal move downward as the engine speed returns to idle?
  
  Yes
  
  GO to O4.
  
  No
  
  Check the vacuum to the brake booster
O4: CHECK THE FRONT WHEEL BEARING ASSEMBLY
1. Check the front wheel bearing assembly
  Are the front wheel bearings loose/damaged?
  
  Yes
  
  Tighten to specification or install a new front wheel bearing as required. Re-test the system for normal operation
  
  No
  
  Check the front brake discs for thickness variances