Brake Pedal Excessive Travel. Chevrolet PJJ 2000

For 1990-2009 cars

Step | Action | Value(s) | Yes | No
--- | --- | --- | --- | ---
1 | Was the Hydraulic Brake Diagnostic System Check performed? | -- | Go to Step 2 | Go to Hydraulic Brake Diagnostic System Check

2

Inspect the disc brake pads and brake shoe linings for the following:

• | Excessive wear

• | Contaminated lining material

• | Uneven wear

• | Glazing

• | Abuse

• | Incorrect lining material

Refer to Brake Pad Inspection in Disc Brakes or Brake Shoe Inspection in Drum Brakes.

Do any of the above conditions exist?

--

Go to Step 3

Go to Step 4

3 | Replace the brake linings. Refer to Brake Pads Replacement in Disc Brakes or Brake Shoe Replacement in Drum Brakes. Is the repair complete? | -- | Go to Hydraulic Brake Diagnostic System Check | --

4

Inspect the brake rotors for the following:

• | Hot spots

• | Scored rotor surface

• | Grooved rotor surface

• | Excessive lateral runout

Refer to Brake Rotor Lateral Runout Check in Disc Brakes

Do any of the above conditions exist?

--

Go to Step 5

Go to Step 6

5

Resurface the brake rotor. Refer to Brake Rotor Refinishing in Disc Brakes.

If refinishing the brake rotor results in a thickness that is less than the thinnest (Refinishing) thickness, replace the rotor. Refer to Brake Rotor Replacement in Disc Brakes.

Is the repair complete?

--

Go to Hydraulic Brake Diagnostic System Check

--

6 | Inspect the drum brakes for improper adjustment. Refer to Drum Brake Adjustment in Drum Brakes. Are the brakes improperly adjusted? | -- | Go to Step 7 | Go to Step 8
7 | Adjust the drum brakes properly. Refer to Drum Brake Adjustment in Drum Brakes. Is the repair complete? | -- | Go to Hydraulic Brake Diagnostic System Check | --
8 | Inspect the brake assembly for missing or loose attachments. Refer to Brake Pad Inspection in Disc Brakes or Brake Shoe Inspection in Drum Brakes. Are there any missing or loose attachments? | -- | Go to Step 9 | Go to Step 10
9 | Replace or tighten the attachments as necessary. Is the repair complete? | -- | Go to Hydraulic Brake Diagnostic System Check | --
10 | Inspect the wheel cylinders and calipers for leakage. Are any of the components leaking? | -- | Go to Step 11 | Go to Step 12
11 | Replace the leaking components. Refer to Brake Caliper Replacement in Disc Brakes or Wheel Cylinder Replacement in Drum Brakes? Is the repair complete? | -- | Go to Hydraulic Brake Diagnostic System Check | --
12 | Inspect the hydraulic brake system for leaks. Refer to Brake Fluid Leak . Is there any sign of leakage? | -- | Go to Step 13 | Go to Step 14
13 | Tighten the brake hose or pipe fittings. Refer to Fastener Tightening Specifications . Is the repair complete? | -- | Go to Hydraulic Brake Diagnostic System Check | --
14 | Inspect the master cylinder for leakage. Refer to Master Cylinder Diagnosis . Is the master cylinder leaking? | -- | Go to Step 15 | Go to Step 16
15 | Replace the master cylinder. Refer to Master Cylinder Replacement . Is the repair complete? | -- | Go to Hydraulic Brake Diagnostic System Check | --
16 | Inspect the brake system for air. Refer to Hydraulic Brake System Bleeding . Is there air in the system? | -- | Go to Step 17 | Go to Step 18
17 | Bleed the brake system. Refer to Hydraulic Brake System Bleeding . Is the repair complete? | -- | Go to Hydraulic Brake Diagnostic System Check | --
18 | Inspect the brake fluid for contamination. Refer to Master Cylinder Reservoir Filling . Is the brake fluid contaminated? | -- | Go to Step 19 | Go to Step 20

19

1. Replace all rubber brake system components. Refer to the following procedures:

• | Master Cylinder Replacement in Disc Brakes.

• | Front Brake Hose Replacement in Disc Brakes.

• | Rear Brake Hose Replacement in Disc Brakes.

• | Brake Caliper Replacement in Disc Brakes.

• | Wheel Cylinder Overhaul in Drum Brakes.

2. Flush the hydraulic brake system. Refer to Hydraulic Brake System Flushing .

Is the repair complete?

--

Go to Hydraulic Brake Diagnostic System Check

--

20 | Verify the proper brake system operation. Does the original condition still exist? | -- | Go to Step 1 | System OK