Pontiac Repair: 1998 Pontiac Transport Brake System, wheel drive cars, front wheel drive cars

Question
Hi Kris:

I am changing the brakes on my friend's '98 Pontiac Transport. I replaced the rear shoes and drums this past Saturday and will be replacing the rotors and pads this weekend.  Before I changed out the rears, I test drove the vehicle and noticed excessive pedal travel.  I thought the condition might be attributed to brake shoe/pad wear, but when I pulled the drums and shoes, I discovered minimal wear on both shoe and drum (the shoes were "glassy").  After replacing the shoes and drums, I bled the rears at the brake plate and adjusted the shoes (both at the adjuster and by braking in reverse).  The pedal travel did not change.  I quickly inspected the front rotors through the rims and noticed to significant wear or grooves.  When I replace the front brakes this weekend, is there anything I should be looking for that may cause this excessive travel?  I'm hopeful I will find wear or a bad caliper or even air in the system.  If everything checks out OK, what direction should I take?  She tells me that the fronts were done "two or three" years ago, but could not recall the extent of the repair.  The master cylinder appears to be original. She is your typical "soccer Mom" who logs a lot of city driving.  Currently, there is 120,000 miles on this vehicle.  Your input and suggestions would be greatly appreciated.  Thanks in advance for your assistance.

Bill

Answer
Well your instinct that the rotors may be causing this might be correct. The rotors may be "dished" or have the center part that the pads contact lower than the outer areas which will cause the calipers to have to push out further for complete pad contact. Other areas to look for especially on the Transport and almost all GM front wheel drive cars are the brake hoses. They have a bad tendency of dry rotting and breaking the outer layer right where the metal strap that holds them to the strut is. I would also look for signs that the calipers are starting to leak with 120k on them. While you have the pads out, gently pull the rubber boot that goes around the piston back and look for fluid leakage. Be careful not to mistake assembly fluid for brake fluid though, when you rub the fluid between your fingers brake fluid will dry out your skin. Last if you still have a bad pedal then the master would be the suspect. The internal seals may be bad and not alowing it to build up the proper amount of pressure causing the "weak" feeling you have. Hope this helps you out Bill and good luck! :)