Brake Pedal Height, Free Play & Stoplight Switch
NOTE:
Pedal free play is measured after turning engine OFF and depressing brake pedal 5 times to release power brake unit power assist.
The push rod serves as the brake pedal stopper when the pedal is fully released.
- Ensure brake pedal is fully returned by pedal return spring. Start engine and rev several times to charge vacuum booster. Measure pedal height and free play. See Fig 1. Adjust pedal height to 6.81-7.28" (173-185 mm). Adjust pedal free play to 0.24-0.39" (6-10 mm). If pedal is not within specifications, go to next step.
- To adjust brake pedal, disconnect stoplight switch harness connector. Loosen stoplight switch lock nut and rotate the stoplight switch so that it moves away from the brake pedal. Loosen push rod lock nut. Adjust the brake pedal to the specified height by rotating the push rod in the appropriate direction. Tighten push rod lock nut to 15 ft. lbs. (20 N.m).
- Start engine and rev several times to charge vacuum booster. 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 3.7" (95 mm) or more. If depressed pedal height is lower than specified, air may still be present in the hydraulic system. Bleed the system. See BLEEDING PROCEDURE under BLEEDING BRAKE SYSTEM.
- While adjusting the stoplight switch, make sure that the threaded part of the stoplight switch does not push the brake pedal. Adjust the stoplight switch to the specified clearance (between the switch housing and the brake pedal) by rotating the switch housing. See Fig 1. Stoplight switch clearance should be 0-0.08" (0-0.2 mm). Tighten the stoplight switch lock nut. Connect the stoplight switch connector.