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Home >> Lexus >> 2005 >> RX 330 FWD >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Brakes - Mechanical >> Brake Pedal Sub-ASSY >> Replacement

Brake Pedal Sub-ASSY: Replacement

  1. REMOVE FRONT DOOR SCUFF PLATE LH 
  2. REMOVE INSTRUMENT PANEL FINISH PANEL SUB-ASSY LOWER (See step 21 in  REPLACEMENT  ) 
  3. REMOVE INSTRUMENT PANEL AIR BAG ASSY LOWER NO. 1 (See  REPLACEMENT  ) 
  4. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSY (See step 22 in  REPLACEMENT  ) 
  5. REMOVE COMBINATION METER ASSY (See step 23 in  COMBINATION METER  ) 
  6. REMOVE BRAKE PEDAL RETURN SPRING 
    1. Remove the brake pedal return spring.
  7. REMOVE PUSH ROD PIN 
    1. Remove the clip and the push rod pin.
    2. Disconnect the stop lamp switch connector.
    3. Disconnect the pedal force switch connector and release the clip of the pedal force switch.
      4. Fig 1: Removing Push Rod Pin
      G03006676Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE BRAKE PEDAL SUPPORT ASSY 
    1. Remove the bolt, the 4 nuts and the brake pedal support assy.
      Fig 2: Removing Brake Pedal Support Assy
      G03006677Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE BRAKE PEDAL SUB-ASSY 
    1. Remove the nut, the brake pedal shaft and the brake pedal sub-assy from the brake pedal support sub-assy.
  10. REMOVE BRAKE PEDAL PAD 
    1. Remove the brake pedal pad from the brake pedal sub-assy.
  11. REMOVE STOP LAMP SWITCH ASSY 
    1. Loosen the stop lamp switch lock nut and remove the stop lamp switch assy.
  12. REMOVE BRAKE PEDAL BUSH 
    1. Remove the 2 brake pedal bushes from the brake pedal sub-assy.
  13. REMOVE BRAKE PEDAL SHAFT COLLAR 
    1. Remove the brake pedal shaft collar from the brake pedal sub-assy.
      Fig 3: Removing Brake Pedal Bush And Shaft Collar
      G03006678Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. REMOVE STOP LAMP SWITCH CUSHION 
    1. Remove the stop lamp switch cushion from the brake pedal sub-assy.
  15. INSTALL STOP LAMP SWITCH CUSHION 
    1. Install the stop lamp switch cushion to the brake pedal sub-assy.
  16. INSTALL BRAKE PEDAL SHAFT COLLAR 
    1. Apply lithium soap base glycol grease to the ends and sides of brake pedal shaft collar.
    2. Install the brake pedal shaft collar to the brake pedal sub-assy.
  17. INSTALL BRAKE PEDAL BUSH 
    1. Apply lithium soap base glycol grease to the ends and sides of 2 new brake pedal bushes.
    2. Install the new brake pedal bushes to the brake pedal sub-assy.
      3. Fig 4: Installing Brake Pedal Bush
      G03006679Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  18. INSTALL STOP LAMP SWITCH ASSY 
    1. Install the stop lamp switch assy with the stop lamp switch lock nut.

      Torque: 17 N.m (173 kgf.cm, 13 ft.lbf) 

      HINT:

      After adjusting the brake pedal height, torque the lock nut.

  19. INSTALL BRAKE PEDAL PAD 
    1. Install the brake pedal pad to the brake pedal sub-assy.
  20. INSTALL BRAKE PEDAL SUB-ASSY 
    1. Install the brake pedal sub-assy with the brake pedal shaft and the nut.

      Torque: 37 N.m (375 kgf.cm, 27 ft.lbf) 

  21. INSTALL BRAKE PEDAL SUPPORT ASSY 
    1. Install the brake pedal support assy with the bolt and the 4 nuts.

      Torque: 

      Bolt: 20 N.m (204 kgf.cm, 15 ft.lbf) 

      Nut: 13 N.m (130 kgf.cm, 9 ft.lbf) 

      Fig 5: Installing Brake Pedal Support Assy With Bolt And Nuts
      G03006680Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  22. INSTALL PUSH ROD PIN 
    1. Apply lithium soap base glycol grease to the clevis pin.
    2. Install the clevis pin and the clip.
    3. Connect the pedal force switch connector and install the clip of the pedal force switch to the brake pedal support sub-assy.
    4. Connect the stop lamp switch connector.
      5. Fig 6: Installing Push Rod Pin
      G03006681Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  23. INSTALL BRAKE PEDAL RETURN SPRING 
    1. Install the brake pedal return spring.
  24. CHECK AND ADJUST BRAKE PEDAL HEIGHT (See  BRAKE PEDAL SUB-ASSY  ) 
  25. CHECK PEDAL FREE PLAY (See  BRAKE PEDAL SUB-ASSY  ) 
  26. CHECK PEDAL RESERVE DISTANCE (See  BRAKE PEDAL SUB-ASSY  ) 
  27. INSTALL COMBINATION METER ASSY 
  28. INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSY 
  29. INSTALL INSTRUMENT PANEL AIR BAG ASSY LOWER NO. 1 (See  REPLACEMENT  ) 
  30. INSTALL INSTRUMENT PANEL FINISH PANEL SUB-ASSY LOWER 
  31. INSTALL FRONT DOOR SCUFF PLATE LH 
  32. INSPECT SRS WARNING LIGHT (See  DIAGNOSIS SYSTEM  ) 
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