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Brake Pedal Height, Free Play & Stoplight Switch

WARNING: This page does not describe the selected car, but rather 7 other vehicles, including the 2001 Isuzu VehiCROSS, 2001 Isuzu Trooper, 2000 Isuzu VehiCROSS, 2000 Isuzu Trooper, and 1999 Isuzu VehiCROSS. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Push rod serves as brake pedal stopper when brake pedal is fully released. Pedal free play is measured with engine off, and brake pedal depressed 5 times to release power brake unit power assist.
  1. Ensure brake pedal is fully returned by pedal return spring. Start engine and rev several times to charge vacuum booster. Measure pedal height from upper foot rest portion of pedal pad to floor board. See Fig 1 . Adjust pedal height to specification. See BRAKE PEDAL HEIGHT SPECIFICATIONS  table.
  2. To adjust pedal height, disconnect stoplight switch harness connector. Loosen stoplight switch lock nut to ensure brake pedal is fully returned. Loosen push rod lock nut. Rotate push rod to obtain specified pedal height. Tighten push rod lock nut to 15 ft. lbs. (20 N.m).
  3. Turn engine off. Depress brake pedal firmly at least 5 times to discharge vacuum booster. Check pedal free play. See Fig 1 . Ensure free play is .24-.39" (6-10 mm). If free play is not within specifications, repeat steps 1)  and 2)  .
  4. Check depressed pedal height. See Fig 1 . With at least 110 lbs. (50 kg) stepping force applied to brake pedal, depressed pedal height should be as specified. See DEPRESSED BRAKE PEDAL HEIGHT SPECIFICATIONS  table. If depressed pedal height is not as specified, repeat steps 1)  and 2)  .
  5. After brake pedal height, free play and depressed height are to specification, install and adjust stoplight switch clearance "A" between stoplight switch housing (not actuating pin) and brake pedal tab to .020-.039" (.5-1.0 mm). See Fig 1 . Tighten stoplight switch lock nut. Reconnect stoplight switch harness connector.
BRAKE PEDAL HEIGHT SPECIFICATIONS

Application In. (mm)
Trooper 8.19-8.58 (208-218)
VehiCROSS 6.81-7.28 (173-185)
DEPRESSED BRAKE PEDAL HEIGHT SPECIFICATIONS

Application In. (mm)
Trooper 3.94 (100)
VehiCROSS 2.17 (55)
Fig 1: Adjusting Brake Pedal Height & Free Play (Typical)
G90E02973Courtesy of ISUZU MOTOR CO.
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