I decided to look at this problem today. It's been bugging me since we bought it in Sept. since it seemed like the pedals were near the far aft end of the travel range.

After doing some isolating of the system, I narrowed it down to the gear box or pedal assembly for the brake pedal. So I took the cover off of the brake pedal gearbox. This will require disconnecting the cable from it. To do this, you lightly squeeze the plastic retainer on the end of the cable to allow it to slide off the gearbox. Removing the gearbox cover requires removing three torx screws and popping two snap tabs out their slots. After removing the cover, I discovered the problem. The gear on the jackshaft is cracked.

It appears to be a plastic gear molded or pressed over a threaded metal insert that turns on the jack shaft. The crack in the plastic gear limits it to one full rotation before the spiral gear hits the crack. So all it will do is run back and forth by one gear rotation, which only moves the pedals a little more than 3/8".

Since the position sensor is on the accelerator pedal end of the cable, I left the cable disconnected from the brake pedal end. This allows at least the accelerator to work through its full range and still have the memory function. I left the cover off of the brake pedal gear box, which allows rotating the gear by hand to get the brake pedal adjusted to a position that is comfortable for everyone that drives our Expy.
Now I will keep watching the local wrecking yards for a brake pedal assembly I can scavenge.

I hope this helps others troubleshoot the small movement of the adjustable pedals problem that seems to be so common.

 

Thanks for the lead RV.. I have been living with the dead pedal assembly for a number of months.. Just haven't put in the time to figure it out.. I have a 2005 EXP EB, and will check it out and see if its the same thing.