Brake Pedal 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 CHECK

1. Turn up the floor carpet under the brake pedal.

2. Remove the stoplight switch (Refer to Service and Repair).





3. Use a needle or similar tool to measure the dimension A in the figure (distance from the dash panel pad surface to the dash panel).
4. Measure the dimension B in the figure (distance from the pedal pad surface to the dash panel pad surface).
5. Make sure that the total of the dimensions A and B measured in Steps 2 and 3 (brake pedal height) is within the standard value.
Standard value (A+B): 219.8 - 227.8 mm (8.7 - 9.0 inch)






6. When the brake pedal height is not within the standard value, inspect the brake pedal in the following procedure.
(1) Remove the brake pedal assembly (Refer to Service and Repair).
(2) Check the removed brake pedal assembly for distortion, and replace it when deformed
(Refer to Brake Pedal Distortion Check).
(3) Install the brake pedal assembly (Refer to Service and Repair).
(4) Measure the brake pedal height again, and make sure that it is within the standard value
(A+B).
When the measured value is not within the standard value, measure the dimension C in the figure (distance from the stud bolt end to the clevis hole center), and make sure it is within the standard value (C).
Standard value (C): 74 mm (2.91 inch)
(5) When the measured value is not within the standard value (C), replace the brake booster
(Refer to Service and Repair).





7. After checking the brake pedal height, install the stoplight switch in the following procedure:
(1) Pull and hold the brake pedal by hand. Insert the stoplight switch until the stoplight switch body contacts the pedal stopper, then turn the switch approximately one eighth of a clockwise turn to fix it.
(2) Check that the clearance between the stoplight switch and the pedal stopper is as shown in the figure.
(3) Connect the stoplight switch connector.
NOTE:
Make sure that the stoplight is not illuminated when the brake pedal is not depressed.

8. Check the shift lock mechanism [TC-SST] Shift Lock Mechanism Check).
9. Recover the floor carpet under the brake pedal.

BRAKE PEDAL FREE PLAY CHECK AND ADJUSTMENT





1. With the engine stopped, depress the brake pedal 2 or 3 times to release the vacuum in the brake booster. Then, press the brake pedal with your finger and check if the pedal stroke until the pedal becomes heavy (play) is within the standard value.
Standard value (D): 3 - 8 mm (0.12 - 0.31 inch)
2. When the brake pedal free play is not within the standard value, check the brake pedal-to-clevis pin looseness, clevis pin-to-booster operating rod looseness, brake pedal height, and stoplight switch position, and adjust or replace as necessary.

BRAKE PEDAL-TO-FLOOR PANEL CLEARANCE CHECK AND ADJUSTMENT

1. Turn up the floor carpet or other similar material under the brake pedal.

2. Using a needle or similar tools, measure the dimension E shown in the figure (from the dash panel pad surface to the dash panel).





3. Start the engine, and depress the brake pedal with approximately 500 N. Then, measure the dimension F shown in the figure (from the center of pedal pad surface to the dash panel pad surface).
4. Check that the sum of the dimensions E and F measured in Steps 2 and 3 (clearance between the brake pedal and the floor panel) is within the standard value.
Standard value (E+F): 85 mm (3.35 inch) or more
5. If the clearance between the brake pedal and the floor panel is not within the standard value, check for the air intrusion in brake line and the thickness of disk brake pad. Make corrections or replace components as necessary.
6. Recover the floor carpet or other similar material under the brake pedal.