Brake Pedal Assy: Testing and Inspection

REQUIRED TOOL: J 28662 Brake Pedal Effort Gauge or equivalent.

1. With engine off and key "Off", pump service brake pedal until all reserve is exhausted from the brake booster.
2. Install Brake Pedal Effort Gauge onto the brake pedal.
3. Hook end of tape measure over top edge of brake pedal and measure the distance to the rim of the steering wheel.
4. Apply service brake pedal with a firm force (approximately 445 N 100 lbs.) and re-measure. The difference between both readings is the actual pedal travel and should not exceed 63 mm (2.5 inches).
5. If pedal travel is greater than 63 mm (2.5 inches) drive the vehicle backward while intermittently applying the brakes. In rare cases excessive pedal travel will develop if brakes are only used occasionally when backing up. This will develop when the vehicle is only occasionally driven in reverse. Duo-Servo self-adjusting mechanisms will only actuate when the brakes are applied in reverse.

NOTE: Most low pedal problems are caused by air in the hydraulic system. This means that the system should be bled until all air is purged. Other less frequent causes of excessive pedal travel are incorrect brake booster push-rod length, improperly adjusted parking brake, rear shoe adjusters not functioning, shoes excessively worn, and hydraulic system leakage.