Brake Pedal Assy: Testing and Inspection

ON-VEHICLE INSPECTION






1. Check pedal height.
Pedal height from asphalt sheet: 152.0 - 162.0 mm (5.984 - 6.378 inch)
2. If necessary, adjust pedal height.
a. Disconnect the connector from the stop light switch.
b. Loosen the stop light switch lock nut and remove the stop light switch.
c. Loosen the push rod lock nut.
d. Adjust the pedal height by turning the pedal push rod.
e. Tighten the push rod lock nut.
Torque: 25 Nm (19 ft. lbs.)
f. Install the stop light switch and turn it until it lightly contacts the pedal stopper.
g. Turn the stop light switch back one turn.





h. Check the clearance (A) between the stop light switch and pedal.
Clearance: 0.5-2.4 mm (0.020-0.094 inch)
i. Tighten the stop light switch lock nut.
j. Connect the connector to the stop light switch.
k. Check that the stop lights come on when the brake pedal is depressed, and go off when the brake pedal is released.
l. After adjusting the pedal height, check the pedal freeplay.

HINT: If clearance (a) between the stop light switch and the pedal stopper has been adjusted correctly, the pedal freeplay will meet the specifications.






3. Check pedal freeplay.
a. Stop the engine and depress the brake pedal several times until there is no more vacuum left in the booster.
b. Push in the pedal by hand until the resistance begins to be felt, then measure the distance.
Pedal freeplay: 1 - 6 mm (0.04 - 0.24 inch)

HINT: The freeplay to the 1st resistance is due to the play between the clevis and pin. This is magnified up to 1 - 6 mm (0.04 - 0.24 inch) at the pedal.

If incorrect, check the stop light switch clearance. If the clearance is OK, then troubleshoot the brake system.





4. Check pedal reserve distance.
a. Release the parking brake.
b. With the engine running, depress the pedal and measure the pedal reserve distance. as shown.
Pedal reserve distance from asphalt sheet at 490 N (110.2 lbs): More that 70 mm (2.76 inch)
If the reserve distance is incorrect, troubleshoot the brake system.