Brake Pedal Assy: Adjustments

BRAKE: BRAKE PEDAL: ADJUSTMENT

ADJUSTMENT

1. INSPECT AND ADJUST BRAKE PEDAL HEIGHT





(a) Check the brake pedal height.
Pedal height from asphalt sheet (MT):
146.6 to 156.6 mm (5.772 to 6.165 in.)
Pedal height from asphalt sheet (AT for 2WD):
151.8 to 161.8 mm (5.976 to 6.370 in.)
Pedal height from asphalt sheet (AT for 4WD):
165.3 to 175.3 mm (6.508 to 6.902 in.)
(b) Adjust brake pedal height.
(1) Disconnect the connector from the stop light switch assembly.
(2) Loosen the stop light switch lock nut. Turn the switch in order to give the pedal some freeplay.
(3) Remove the brake booster assembly. Removal




(4) Loosen the push rod lock nut, turn the push rod clevis and adjust dimension "A" shown in the illustration.
Dimension "A":
146.2 to 147.2 mm (5.756 to 5.795 in.)
(5) Tighten the push rod lock nut.
Torque: 26 Nm (265 kgf-cm, 19 ft-lbf)
(6) Install the brake booster assembly. Installation




(7) Turn the stop light switch assembly so that the clearance between the switch and the area where the pedal makes contact is between 0.5 and 2.4 mm (0.020 to 0.095 in.). Tighten the lock nut.
Torque: 17 Nm (170 kgf-cm, 12 ft-lbf)
(8) Connect the connector to the stop light switch assembly.
2. INSPECT PEDAL FREE PLAY
(a) Stop the engine and depress the brake pedal several times until no vacuum is left in the booster.





(b) Press the pedal until a slight resistance is felt. Measure the distance as shown in the illustration.
Pedal free play:
1.0 to 2.0 mm (0.039 to 0.079 in.)
If the pedal free play is 1 mm (0.04 in) or less, check the protrusion of the stop light switch assembly shaft.
Protrusion of the stop light switch assembly shaft:
0.5 to 2.4 mm (0.020 to 0.095 in.)
If the protrusion is not within the specified range, adjust it.
If the protrusion is within the specified range, it is normal though brake pedal free play is 1.0 mm (0.039 in.) or less.
3. INSPECT PEDAL RESERVE DISTANCE





(a) Release the parking brake pedal.
(b) With the engine running, depress the pedal and measure the pedal reserve distance as shown in the illustration.
Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110 lbf):
2GR-FSE, 6AT
More than 105 mm (4.13 in.)
4GR-FSE, 6AT
More than 108 mm (4.25 in.)
4GR-FSE, 6MT
More than 104 mm (4.09 in.)
If incorrect, troubleshoot the brake system. Testing and Inspection