Brake Pedal Assy: Testing and Inspection
BRAKE PEDAL CHECK AND ADJUSTMENTBRAKE PEDAL HEIGHT
1. 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. Loosen the stoplight switch by turning it approximately 4 turns anticlockwise.
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. Insert the stoplight switch until its threaded part touches the stopper. Then lock the stoplight switch by turning it approximately 1/4 turn clockwise, and confirm that the clearance between the switch plunger and the stopper is as shown.
CAUTION: Check that the stoplight does not illuminate when the brake pedal is not depressed.
8. Connect the connector at the stoplight switch.
4. Return the carpet, etc.
BRAKE 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 down by hand, and confirm that the amount of movement before resistance is met (the free play) is within the standard value.
Standard value (B): 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 500 N (112 pounds) 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 the floorboard to the face of pedal pads
3. If the clearance is outside the standard value, check for air trapped in the brake line and thickness of the disc brake pad. And then bleed the air and replace the disc brake pad as required.
4. Return the carpet etc. to its original position.