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. Remove the No. 1 lower panel and lower LH panel.
b. Disconnect the connector from the stop light switch.
c. Loosen the stop light switch lock nut and remove the stop light switch.
d. Loosen the push rod lock nut.
e. Adjust the pedal height by turning the pedal push rod.
f. Tighten the push rod lock nut.
Torque: 25 Nm (260 kgf-cm, 19 ft. lbs.)
g. Install the stop light switch.
h. Push the brake pedal in 5 - 15 mm (0.20 - 0.59 inch), turn the stop light switch to lock the nut in a position where the stop light goes off.
i. Connect the connector to the stop light switch.
j. After installation, push the brake pedal in 5 - 15 mm (0.20 - 0.59 inch), check that stop light lights up.
k. After adjusting the pedal height, check the pedal freeplay.
l. Install the lower LH panel and No. 1 lower panel.





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.

Stop light switch clearance: 0.5 - 2.4 mm (0.020 - 0.094 inch)





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 (50 kgf, 110.2 lbs.): More than 70 mm (2.76 inch)
If the reserve distance is incorrect, troubleshoot the brake system.