LEMON Manuals: Even more car manuals for everyone
Home >> Lexus >> 2006 >> GX 470 >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Brakes - Mechanical >> Brake Pedal Support ASSY >> Overhaul

Brake Pedal Support ASSY: Overhaul

  1. REMOVE FRONT DOOR SCUFF PLATE LH (SEE  REPLACEMENT  ) 
  2. REMOVE FRONT FLOOR FOOTREST (SEE  REPLACEMENT  ) 
  3. REMOVE COWL SIDE TRIM BOARD LH (SEE  REPLACEMENT  ) 
  4. REMOVE INSTRUMENT CLUSTER FINISH PANEL ORNAMENT (SEE  REPLACEMENT  ) 
  5. REMOVE INSTRUMENT PANEL FINISH PLATE (SEE  REPLACEMENT  ) 
  6. REMOVE INSTRUMENT PANEL FINISH LOWER PANEL RH (SEE  REPLACEMENT  ) 
  7. REMOVE INSTRUMENT PANEL LOWER LH (SEE  REPLACEMENT  ) 
  8. REMOVE INSTRUMENT PANEL JUNCTION BLOCK ASSY 
  9. REMOVE BRAKE PEDAL PAD 
  10. REMOVE PUSH ROD PIN 
    1. Remove the clip and push rod pin from the brake pedal lever.
  11. REMOVE BRAKE PEDAL SUPPORT ASSY 
    1. Disconnect the stop lamp switch connector from the stop lamp switch assy.
    2. Remove the bolt from the brake pedal support reinforcement.
      Fig 1: Removing Bolt From Brake Pedal Support Reinforcement
      G02963436Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Loosen the bolt and nut.
      Fig 2: Loosening Bolt & Nut
      G02963437Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Remove the 4 nuts and brake pedal support sub-assy.
      Fig 3: Removing Nuts & Brake Pedal Support Sub-Assy
      G02963438Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. REMOVE BRAKE PEDAL RETURN SPRING 
  13. REMOVE BRAKE PEDAL 
    1. Remove the bolt and nut, then remove the brake pedal support reinforcement from the brake pedal support sub-assy.
    2. Remove the bolt and nut, then remove the brake pedal sub-assy from the brake pedal support assy.
    3. Remove the 4 brake pedal bushes from the brake pedal and brake pedal lever.
    4. Remove the 2 collars from the brake pedal sub-assy and brake pedal lever.
      Fig 4: Removing Bolt & Nut
      G02963439Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    5. Using a screwdriver, remove the 2 E-rings from the brake pedal link pin.
    6. Remove the 2 brake pedal link pins, 2 brake pedal shaft collars and 2 brake pedal links.
    7. Remove the brake pedal lever from the brake pedal sub-assy.
      Fig 5: Removing E-Rings From Brake Pedal Link Pin Using Screwdriver
      G02963440Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  14. INSTALL BRAKE PEDAL 
    1. Apply the lithium soap base glycol grease to the 2 brake pedal link pins, 2 pedal shaft collars and 2 brake pedal links.
    2. Install the brake pedal lever with 2 brake pedal link pins, 2 brake pedal shaft collars and 2 brake pedal links to the brake pedal sub-assy.
    3. Install the 2 new E-rings to each of the brake pedal link pins.
    4. Apply the lithium soap base glycol grease to the 2 collars and 4 brake pedal bushes.
    5. Install the 2 collars and 4 brake pedal bushes to the brake pedal sub-assy and brake pedal lever.
    6. Install the brake pedal sub-assy with a bolt and nut to the brake pedal support sub-assy.

      Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) 

      Fig 6: Installing Brake Pedal Sub-Assy With Bolt & Nut
      G02963441Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  15. INSTALL BRAKE PEDAL RETURN SPRING 
    1. Apply the lithium soap base glycol grease to inner surface of the hole on the brake pedal support sub-assy.
    2. Install the brake pedal return spring to the brake pedal support sub-assy.
  16. INSTALL BRAKE PEDAL SUPPORT ASSY 
    1. Install the 4 nuts and brake pedal support sub-assy.

      Torque: 14.2 N.m (145 kgf.cm, 10 ft.lbf) 

    2. Install the brake pedal support reinforcement to the brake pedal support sub-assy.
      Fig 7: Installing Nuts & Brake Pedal Support Sub-Assy
      G02963442Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Temporarily tighten the bolt and nut to the brake pedal support sub-assy, brake pedal support reinforcement and brake pedal lever.
      Fig 8: Tightening Bolt & Nut To Brake Pedal Support Sub-Assy, Brake Pedal Support Reinforcement & Brake Pedal Lever
      G02963443Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    4. Install the bolt to the brake pedal support reinforcement.

      Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) 

    5. Tighten the bolt and nut.

      Torque: 34.3 N.m (350 kgf.cm, 25 ft.lbf) 

      Fig 9: Installing Bolt To Brake Pedal Support Reinforcement
      G02963444Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  17. INSTALL PUSH ROD PIN 
    1. Apply the lithium soap base glycol grease to the inner surface of the hole on the brake pedal lever.
    2. Install the push rod pin and clip to the brake pedal lever.
  18. INSTALL BRAKE PEDAL PAD 
  19. INSTALL INSTRUMENT PANEL JUNCTION BLOCK ASSY 
  20. INSTALL INSTRUMENT PANEL LOWER LH 
  21. INSTALL INSTRUMENT PANEL FINISH LOWER PANEL RH 
  22. INSTALL INSTRUMENT PANEL FINISH PLATE 
  23. INSTALL INSTRUMENT CLUSTER FINISH PANEL ORNAMENT 
  24. INSTALL COWL SIDE TRIM BOARD LH 
  25. INSTALL FRONT FLOOR FOOTREST 
  26. INSTALL FRONT DOOR SCUFF PLATE LH 
  27. INSPECT BRAKE PEDAL HEIGHT (See  ON-VEHICLE INSPECTION   ) 
  28. CHECK PEDAL FREE PLAY (See  ON-VEHICLE INSPECTION   ) 
  29. CHECK PEDAL RESERVE DISTANCE (See  ON-VEHICLE INSPECTION   ) 
  30. CHECK VSC SENSOR SIGNAL (SEE  TEST MODE PROCEDURE  ) 
scientia non olet · About LEMON Manuals