Brake Pedal: Adjustment

CHECK AND ADJUST BRAKE PEDAL HEIGHT
1. Check brake pedal height.
  Pedal height from asphalt sheet:
  
  150.0 to 160.0 mm (5.906 to 6.299 in.)
2. Adjust brake pedal height.
  1. Disconnect the connector from the stop light switch assembly.
  2. Loosen the stop light switch lock nut and remove the stop light switch assembly.
  3. Loosen the push rod lock nut.
  4. Adjust the pedal height by turning the pedal push rod.
    
    Fig 1: Adjusting Brake Pedal Height
    Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. Tighten the push rod lock nut.
    Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf)
  6. Install the stop light switch assembly.
  7. Connect the connector to the stop light switch assembly.
  8. Push the brake pedal in 5 to 10 mm (0.20 to 0.39 in.), turn the stop light switch assembly to lock the nut in the position where the stop light goes off.
  9. After installation, push the brake pedal in 5 to 10 mm (0.20 to 0.39 in.), and check that the stop light comes on.
  10. Tighten the stop light switch lock nut.
    Torque: 17 N*m (173 kgf*cm, 13 ft.*lbf)
CHECK PEDAL FREE PLAY
1. Stop the engine and depress the brake pedal several times until there is no more vacuum left in the booster.
2. Press the pedal until the beginning of the resistance is felt. Measure the distance as shown below.
  Pedal freeplay:
  
  2.0 to 3.0 mm (0.079 to 0.118 in.)
  
  Fig 2: Identifying Pedal Free Play
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If incorrect, proceed to the following step.
  1. Check the stop light switch clearance.
    Stop light switch clearance:
    
    0.5 to 2.6 mm (0.020 to 0.102 in.)
    
    If correct, the pedal free paly is OK.
    
    If incorrect, adjust the stop light switch clearance.
CHECK PEDAL RESERVE DISTANCE
1. Release the parking brake pedal.
2. With engine running, depress the pedal and measure the pedal reserve distance, as shown below.
  Pedal reserve distance from asphalt sheet at 490 N (50 kgf, 110.2 lbf):
  
  More than 80 mm (3.1 in.)
  
  Fig 3: Checking Pedal Reserve Distance
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  
  If incorrect, troubleshoot the brake system.