Inspection Procedure 3: Increased Pedal Stroke (Reduced Pedal-to-Floor Board Clearance)

INSPECTION PROCEDURE 3: Increased Pedal Stroke (Reduced Pedal-to-Floor Board Clearance)

DIAGNOSIS

STEP 1. Check for spongy (not firm) brakes.
1) With engine not running, depress the brake pedal rapidly several times to deplete booster vacuum reserve.
2) With the brake pedal fully released, depress the brake pedal slowly until it stops.
3) With a measuring device (ruler, etc ) next to the brake pedal, depress the pedal firmly and measure the distance the pedal traveled.
Q: Is the distance greater than 20 mm (0.8 inch)?
YES: Bleed the brakes to remove air in the fluid. Then go to Step 6.
NO: Go to Step 2.

STEP 2. Check the pad for wear.
Q: Is the pad thickness outside of specifications?
YES: Replace the part. Then go to Step 6.
NO: Go to Step 3.

STEP 3. Check the vacuum hose and check valve for damage.
Refer to Testing and Inspection.
Q: Is there a damage?
YES: Replace the part. Then go to Step 6.
NO: Go to Step 4.

STEP 4. Check for brake fluid leaks.
Q: Is there a leak?
YES: Check the connection for looseness, corrosion, etc. Clean and repair as necessary. If leaking in any tube or hose section, replace the complete tube or hose. Then go to Step 6.
NO: Go to Step 5.

STEP 5. Check the master cylinder assembly.
1) Remove the master cylinder assembly.
2) Check for brake fluid leaks from the master cylinder assembly seal.
Q: Is a brake fluid leaking from the master cylinder assembly seal present?
YES: Replace the master cylinder assembly and the brake booster assembly. Then go to Step 6.
NO: Go to Step 6.

STEP 6. Recheck symptom.
Q: Is the symptom eliminated?
YES: The procedure is complete.
NO: Start over at step 1. If a new symptom surfaces, refer to the symptom chart. Symptom Chart