Brake Pedal Assy: Testing and Inspection

BRAKE PEDAL CHECK AND ADJUSTMENT

CAUTION:
Do not apply grease or lubricant to the switch and the switch installation section to avoid malfunction of the switch. In addition, do not use gloves which have grease on them.

BRAKE PEDAL HEIGHT

1. Turn up the carpet, etc. under the brake pedal.





2. Measure the brake pedal height as illustrated.
Standard value: 169.8 - 172.8 mm (6.69 - 6.80 inches)
[From the surface of dash panel to the face of pedal pad]










3. If the brake pedal height is not within the standard value, follow the procedure below.
(1) Disconnect the stoplight switch connector.
(2) Remove the brake booster (Refer to Service and Repair).
NOTE:
With the master cylinder and brake pipe connected, remove the brake booster only.

(3) Adjust the brake pedal height by turning the clevis.
NOTE:
When the clevis is turned 180 degrees, the pedal height is changed by approximately 2.2 mm (0.09 in).

(4) Install the brake booster (Refer to Service and Repair).
(5) Measure the brake pedal height, and ensure that the measured value is within the specified value. If it is out of the specified value, repeat Step (3) - (6).
(6) Screw in the stop light switch until its thread contacts the stopper, then turn it approximately one quarter of a turn clockwise.
(7) Check that the clearance between the stop light switch and the stopper is as shown.
(8)

CAUTION:
Check that the stop light does not illuminate when the brake pedal is not depressed.

Connect the connector at the stop light switch.
4. Check the key interlock and shift lock mechanisms. Key Interlock and Shift Lock Mechanism Check).
5. Return the carpet, etc. to its original position.

BRAKE PEDAL FREE PLAY





1. Turn the ignition switch to the "LOCK" (OFF) position, and 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 stop light switch, etc.

CLEARANCE BETWEEN BRAKE PEDAL AND DASH PANEL

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 dash panel.
Standard value: 110 mm (4.33 inches) or more [From the surface of dash panel to the face of pedal pad]
3. If the clearance is outside the standard value, check for air trapped in the brake line and check the thickness of the disc brake pad. Adjust or replace defective parts as required.
4. Return the carpet etc. to its original position.