THE BRAKE PEDAL ASSEMBLY HAS A PUSHROD PIN THAT IS TOO SMALL AND IT IS INSTALLED IN THE WRONG POSITION, CAUSING AN INCREASED BRAKE PEDAL RATIO AND A DECREASED MASTER CYLINDER STROKE.
THE REDUCED MASTER CYLINDER STROKE RESULTS IN FAILURE TOMEET THE PARTIAL SYSTEM FAILURE REQUIREMENTS OF FMVSS 105, "HYDRAULIC BRAKESYSTEMS". A FURTHER REDUCTION IN BRAKING ABILITY AT A TIME WHEN PARTIAL SYSTEMFAILURE HAS OCCURRED COULD RESULT IN A VEHICLE CRASH.
REPLACE THE BRAKE ASSEMBLY.
SYSTEM: BRAKES: BRAKE PEDAL ASSEMBLY; FMVSS 105.VEHICLE DESCRIPTION: VANS EQUIPPED WITH VACUUM POWER BRAKES.NOTE: FMVSS 105 REQUIRES THAT HYDRAULIC BRAKE SYSTEMS HAVE AN EMERGENCY FEATUREWHICH STOPS THE VEHICLE UNDER SPECIFIED CONDITIONS. ALL HYDRAULIC BRAKE SYSTEMSARE DESIGNED WITH A SPLIT SYSTEM. EACH SPLIT WORKS INDEPENDENTLY FROM THE OTHER.THE PARTIAL SYSTEM FAILURE TEST OF THE FMVSS IS PERFORMED WITH ONE OF THE SPLITSYSTEMS INOPERATIVE.