Brake Pedal Assy: Service and Repair

BRAKE PEDAL





COMPONENT

REMOVAL
1. Disconnect the negative battery cable.
2. Remove the split pin from the brake pedal clevis pin and remove the pin.
3. Remove the pivot bolt attaching nut, lockwasher, and spring washer.
4. Remove the spacer from the pivot bolt.
5. Slide the pivot bolt to the right and remove.
6. Remove the brake pedal, brake pedal return spring, and spacers.
7. If necessary, remove the brake pedal bushings, foot pad, and stop bumper.

BRAKE PEDAL HEIGHT
INSPECTION





Verify that the distance from the center on the pedal pad to the dash lower panel mat is as specified.
Specification: 6.69 - 6.93 inch (170 - 176 mm)

ADJUSTMENT
1. Disconnect the stop light switch connector.
2. Loosen the locknut B and turn the switch A until it does not contact the pedal.
3. Loosen the locknut D and turn the rod C to adjust the height of the brake pedal.
4. Tighten the stop light switch until it contacts the pedal then turn it an additional 1/2 turn. Tighten the locknuts B and D.
Tightening torque: 23.5 - 34.3 Nm (2.4 - 3.5 kg-m, 17.4 - 25.3 ft. lbs.)
5. Verify the operation of the stoplights.

PEDAL PLAY
INSPECTION
1. Depress the pedal a few times to eliminate the vacuum in the system.





2. Gently depress the pedal by hand and check the free play (until resistance is felt).
Free play: 0.16 - 0.28 inch (4 - 7 mm)

ADJUSTMENT
1. Loosen the locknut D and turn the rod C to adjust the free play.
2. Verify the pedal height and the stoplight operation.





3. Tighten a lock nut D.
Tightening torque: 23.5 - 34.3 Nm (2.4 - 3.5 kg-m, 17.4 - 25.3 ft. lbs.)
4. Check the height of pedal and the lightening of stop lamp after the adjustment.

PEDAL-TO-FLOOR CLEARANCE (INSPECTION)





Verify that the distance from the floor panel to the center of the pedal pad is as specified when the pedal is depressed with a force of 490.33 N (50 kg) MIN.
Pedal-to-floor clearance: 2.76 inch (70 mm)
If the distance is less than specified, check for the following problems:
1. Air in brake system
2. Malfunction of automatic adjuster (rear drum brakes)
3. Worn shoes or pads

INSTALLATION
1. If necessary, install the brake pedal stop bumper, foot pad, and bushings.
2. Position the brake pedal spacer and slide the pivot bolt through to hold it in position.
3. Position the return spring on the brake pedal.
4. Position the clutch pedal, if equipped, and slide the pivot bolt through to hold it in position.
5. Install the clutch pedal spacer, if equipped.
6. Install the pivot bolt attaching washers and nut.
7. Install the brake pedal clevis pin and split pin.
8. Connect the negative battery cable.