Brake Pedal Assy: Testing and Inspection

BRAKE PEDAL CHECK AND ADJUSTMENT

BRAKE PEDAL HEIGHT
1. Turn up the carpet etc. under the brake pedal.





2. Measure the brake pedal height as illustrated. If it is not within the standard value, adjust as follows.
Standard value: 175 - 178 mm (6.9 - 7.0 inches) [From the surface of melting sheet (floorboard) to the face of pedal pad]
1) Disconnect the stoplight switch connector.
2) Rotate the stoplight switch 1/4 turn counterclockwise to loosen.





3) Loosen the operating rod jam nut. Turn the serrations of the operation rod with pliers to adjust the brake pedal height to the standard valve.





4) Turn the stoplight switch until it's thread part contacts the stopper. During this step, secure the pedal by moving it forward by hand.
5) Turn the stoplight switch 1/4 turn clockwise to secure. Then confirm that the clearance between the switch plunger and the stopper is as shown.
6) Connect the connector of the stoplight switch.
7) Check to be sure that the stoplight does not illuminate with the brake pedal released
3. Return the carpet, etc. to its original position.

BRAKE PEDAL FREE PLAY





1. Turn the ignition switch to the "LOCK" (OFF) position, depress the brake pedal two or three times. After eliminating the vacuum in the brake booster, press the pedal down by hand, and confirm that the amount of movement before resistance is met (free play) is within the standard value range.
Standard value: 3 - 8 mm (0.12 - 0.31 inch)
2. If the brake pedal play is not within the standard value, check the followings, and adjust or replace if necessary:
^ Excessive play between the brake pedal and the clevis pin, or between the clevis pin and the brake booster operating rod
^ Brake pedal height
^ Installation position of the stoplight switch, etc.

CLEARANCE BETWEEN BRAKE PEDAL AND FLOORBOARD
1. Turn up the carpet etc. under the brake pedal.





2. Start the engine, depress the brake pedal with approximately 490 N (110 pound) of force, and measure the clearance between the brake pedal and the floorboard.
90 mm (3.5 inches) or more [From the surface of melting sheet (floorboard) to the face of pedal pad]
3. If the clearance is outside the standard value, check for air trapped in the brake line and thickness of the disc brake pad. And then adjust and replace defective parts as required.
4. Return the carpet etc. to its original position.