Brakes - Brake Pedal Spongy/Increased Pedal Travel

TECHNICAL

Bulletin No.: 09-05-25-003

Date: September 21, 2009

Subject: Brake Pedal Spongy, Increased Pedal Travel, Increased Effort to Stop (Inspect for Leaks, Replace Brake Pressure Modulator Valve (BPMV), and Bleed Brake System)

Models:
2009 Chevrolet Cobalt
2009 Chevrolet Colorado
2009 Chevrolet Equinox
2009 Chevrolet HHR
2009 GMC Canyon
2009 Pontiac G5
2009 Pontiac Torrent
2009 Pontiac Solstice
2009 Saturn SKY
2009 Saturn VUE
Equipped With RPO JL4 Only

Condition

Some customers may comment that over time the brake pedal has begun to feel spongy, that they are experiencing increased pedal travel and an increased effort to stop.

Cause

This condition may be caused by air accumulating in the master cylinder or by a missing filter in the brake pressure modulator valve (BPMV).

Correction

1. Perform the Diagnostic System Check - Vehicle.

• If DTCs are present, refer to Diagnostic Trouble Code (DTC) List - Vehicle.
• If DTCs are not present, proceed with this bulletin.

2. Inspect the master cylinder for the proper brake fluid level.
3. Visually inspect the brake system for external leaks. Refer to Brake System External Leak Inspection in SI.
4. Verify the customer concern by road testing the vehicle.





Note
Depending on the placement/orientation of the bar code label on the BPMV, it may be necessary to use a mirror to view and identify the 4-digit numbers.

5. Inspect the 4-digit number (1) underneath the bar code on the brake pressure modulator valve and compare it to the following list to verify if it is one of the affected units.

List of Affected Units
- 2428
- 2438
- 2448
- 2458
- 2468
- 2478
- 2488
- 2498

• If the 4-digit number on the BPMV matches one of the above listed numbers, then proceed to Step 6 of this bulletin.
• If the 4-digit number on the BPMV does not match one of the above listed numbers, then refer to Brakes > Antilock Brake Systems and Hydraulic Brakes in SI.

6. Remove and replace the BPMV. Refer to Brake Pressure Modulator Valve Replacement in SI.
7. Fill the brake master cylinder with GM approved brake fluid from a clean sealed brake fluid container.
8. Bleed the brakes. Refer to Hydraulic Brake System Bleeding (Pressure) in SI.
9. Using a scan tool, perform the ABS automated bleeding procedure to remove any air that may have been trapped in the BPMV. Refer to Antilock Brake System Automated Bleed Procedure in SI.
10. Verify the brake fluid level and the proper operation of the brake system before releasing the vehicle to the customer.

Parts Information





Warranty Information





For vehicles repaired under warranty, use the table above.





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