BRAKE PEDAL REMOVAL/INSTALLATION [R.H.D.]

id041100801252

Caution
•  The clearance between the brake switch and the brake pedal is automatically adjusted to the correct amount when the brake switch is inserted into the installation hole on the brake pedal and rotated to fix in place. If the brake switch is not properly installed, the clearance may be incorrect, causing a brake light malfunction. Therefore, always verify that the brake pedal is properly installed and fully released before installing the brake switch to the pedal.
•  Once the brake switch clearance has automatically been adjusted, it cannot be adjusted again. Therefore, replace the switch with a new one when replacing the power brake unit or the pedal, or performing any procedure that changes the pedal stroke.
•  Secure the steering wheel using tape or a cable to prevent the intermediate shaft from rotating after disconnecting the intermediate shaft. If the steering wheel rotates after the intermediate shaft and the steering gear and linkage are disconnected, the internal parts of the clock spring could be damaged.

1.  Disconnect the brake pipes from the master cylinder. (See MASTER CYLINDER REMOVAL/INSTALLATION.)

2.  Disconnect the clutch reserve hose from the master cylinder. (MTX) (See MASTER CYLINDER REMOVAL/INSTALLATION.)

3.  Disconnect the intermediate shaft from the steering gear and linkage. (See INTERMEDIATE SHAFT REMOVAL/INSTALLATION.)

4.  Remove in the order indicated in the table.

5.  Install in the reverse order of removal.

6.  After installation, add brake fluid, bleed the air, and inspect for fluid leakage. (See BRAKE FLUID AIR BLEEDING.)

ac5wzw00000205

1
Brake switch connector and wiring harness
2
Brake switch
(See Brake Switch Installation Note.)
3
Spring pin
4
Clevis pin
5
Nut
6
Nut
7
Brake pedal
(See Brake Pedal Removal Note.)
8
Pedal pad


Brake Pedal Removal Note

1.  Move the power brake unit to the vehicle front where the power brake unit fork does not interfere with the brake pedal arm.

2.  Remove the brake pedal.


Brake Switch Installation Note

1.  Inspect the brake pedal. (See BRAKE PEDAL INSPECTION.)

2.  With the brake pedal fully released, insert a new brake switch into the installation hole on the brake pedal.

3.  Secure the brake switch by turning it counterclockwise 45°.

ac5wzw00000206