GSB 23-7030 - Brake Pedal Travel Measurement Procedure

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While this General Service Bulletin is written for 2019-2023 Ranger models, it's technique of using a tape measure and masking tape on the steering wheel to measure brake pedal travel does provide a measurement that may be useful when describing brake performance issues to a Dealership Service Rep or Professional Service Technician...
GENERAL SERVICE BULLETIN Brake Pedal Travel Measurement Procedure	23-7030 02 March 2023
This bulletin supersedes 22-7059. Model: Ford 2019-2023 Ranger   Summary This article supersedes GSB 22-7059 to update the vehicle model years affected. This article is to assist with determining when brake system repairs are necessary to address the symptom of excessive brake pedal travel (low/spongy pedal).   Brake Pedal Travel Measurement Procedure 1. With the vehicle on a flat surface, place the transmission selector level in park (P). Do not apply the parking brake. 2. With the engine off, push the brake pedal heavily 10 times. This will remove all vacuum from the brake booster. 3. Pedal travel measurement set up: (1). The steering wheel position will need to be: • Straight/centered with the lower opening at the 6 o’clock position. • Up/down (tilt) position is to be at its lowest point. • In/out (telescoping) position should be at its most inward position (toward the brake pedal). (2). Wrap a 2 inch (5 cm) wide strip of low-tac tape through the lower opening of the steering wheel. (3). Extend a tape measure (in centimeters if available) through the lower opening of the steering wheel over the tape that was just installed. Use caution to prevent any damage to the steering wheel. (Figure 1) Figure 1   (4). Secure the end of the tape measure to the left/center side of the brake pedal as shown. A high-tac tape can be used to hold the end of the tape measure in place during the procedure. (Figure 2) Figure 2   (5). Using a ball point pen, draw a line on the tape to create an indicating mark for the tape measure. (Figure 3) Figure 3   (6). The brake pedal travel measurement set up at the steering wheel should look like this. The actual measurement shown below is only an example and should not be used when calculating pedal travel on the vehicle being tested. (Figure 4) Figure 4   4. Ford Diagnosis and Repair System (FDRS) setup: (1). Connect the FDRS to the vehicle and begin a vehicle session. (2). In the FDRS Menu, access User Settings and make sure that the unit of measure for Pressure is set to kPa. (3). Select the toolbox tab and then datalogger from the list on the right side of the screen. (4). On the datalogger module selection screen, select Anti-lock Brake System (ABS) module and Continue. (5). On the parameter identification (PID) list selection screen for the ABS module, select: BRKHYDPRESS.   5. Brake pedal travel measurement: (1). With the brake pedal not-pressed, record the reading of the tape measure at the line draw on the tape on the steering wheel. (Figure 4) (2). While monitoring the BRKHYDPRESS PID in FDRS, slowly press the brake pedal until 1000 kPa is obtained. (3). Record the reading of the tape measure at the line drawn on the tape on the steering wheel while the brake pedal pressure is being held at 1000 kPa. (4). Perform this test a total of 5 times with 30 second intervals after each press of the brake pedal. Document all readings in the chart provided below. (Table 1)   Table 1 Test Number Brake Pedal Not Pressed Measurement (cm) Brake Pedal Pressed Measurement (cm) Calculated Brake Pedal Travel (cm) 1       2       3       4       5           Brake pedal travel average:     6. Is the average brake pedal travel equal to or less than 5.2 cm? (1). Yes - brake pedal travel is within normal range and the brake hydraulic system is operating normally. (2). No - perform a Brake System Pressure Bleeding, refer to Workshop Manual (WSM), Section 206-00 and retest. If the average brake pedal travel is still above the normal range after performing the Brake System Pressure Bleeding procedure, refer to WSM, Section 206-00 for further diagnosis and testing.   © 2023 Ford Motor Company All rights reserved. NOTE: This information is not intended to replace or supersede any warranty, parts and service policy, workshop manual (WSM) procedures or technical training or wiring diagram information.