Brake Pedal Assy: Adjustments

BRAKE PEDAL & BRAKE SWITCH ADJUSTMENT
PEDAL HEIGHT
1. Disconnect the brake switch connector, loosen the brake switch locknut (A), and brake off the brake switch (B) until it is no longer touching the brake pedal.
2. Lift up the carpet. At the insulator cutout, measure the pedal height (C) from the middle of the left-side center of the pedal pad (D).

Standard pedal height (with carpet removed) :
171 mm (6.73 in)





3. Loosen the pushrod locknut (A), and screw the pushrod in or out with pliers until the standard pedal height from the floor is reached. After adjustment, tighten the locknut firmly. Do not adjust the pedal height with the pushrod depressed.





BRAKE SWITCH CLEARANCE
Screw in the brake switch until its plunger is fully depressed (threaded end (A) touching the pad (B) on the pedal arm) then brake off the switch 3/4 turn to make 0.5 - 1.0 mm (0.0197 - 0.0394 in.) of clearance between the brake switch connector. Make sure that the brake lights go off when the pedal is released.





PEDAL FREE PLAY
1. With the engine stopped, depress the brake pedal two or three times. After eliminating the vacuum in the power brake booster, press the pedal(B) down by hand, and confirm that the amount of movement(A) before resistance is met (the free play) is within the standard value.

Standard value : 3 - 8 mm (0.117 - 0.312 in.)





2. If free play does not reach the standard value, check that clearance between the outer case of stop light switch(C) and brake pedal is within the standard value. If free play exceeds the standard value, it is probably due to excessive clearance between the clevis pin and brake pedal arm. Check for excessive clearance and replace faulty parts as required.
3. Start the engine, depress the brake pedal with approximately 120kg (1176.8N, 264.5 lb) of force, and check for oil leakage in the master cylinder, brake line and each connecting part. Repair the faulty parts as required.