Brake Pedal Assy: Testing and Inspection
BRAKE PEDAL HEIGHT1. Turn up the carpet, etc. under the brake pedal.
2. Measure the brake pedal height as illustrated.
Standard value (A): 169.1 - 172.1 mm (6.7 - 6.8 inches) [From the surface of melting sheet (floorboard) to the face of pedal pad]
3. If the brake pedal height is not within the standard value, follow the procedure.
1) Disconnect the stoplight switch connector.
2) If the brake pedal height is not within the standard value, follow the procedure.
3) Remove the brake booster.
NOTE: With the master cylinder and brake pipe connected, remove the brake booster only.
4) Adjust the brake pedal height by turning the clevis.
NOTE: When the clevis is turned 180 degrees, the pedal height is changed approximately 2.4 mm (0.09 inch).
5) Install the brake booster.
6) Measure the brake pedal height, and ensure that the measured value is within the specified value. When it is out of the specified value, repeat Step (3) - (6).
7) Screw in the stop light switch until its thread contacts the stopper, and fix the stop light switch by turning it approximately one quarter of a turn clockwise.
8) Check that the clearance between the stop light switch and the stopper is as shown.
9) Connect the connector at the stoplight switch.
CAUTION: Check that the stop lamp does not illuminate when the brake pedal is not depressed.
4. For A/T models, check the key interlock and shift lock mechanisms.
5. Return the carpet, etc.
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 following, 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.
Standard value (C): 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, thickness of the disc brake pad, clearance between the lining and the drum and dragging in the parking brake. And then adjust and replace defective parts as required.
4. Return the carpet etc. to its original position.