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Brake Pedal Support ASSY: Overhaul

  1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL (SEE  PRECAUTION  ) 
  2. REMOVE FR WIPER ARM & BLADE ASSY LH (SEE  REPLACEMENT  ) 
  3. REMOVE FR WIPER ARM & BLADE ASSY RH (SEE  REPLACEMENT  ) 
  4. REMOVE COWL TOP VENTILATOR LOUVER RH (SEE  REPLACEMENT  ) 
  5. REMOVE WINDSHIELD WIPER MOTOR & LINK ASSY (SEE  REPLACEMENT  ) 
  6. REMOVE COWL TOP PANEL OUTER (SEE  REPLACEMENT  ) 
  7. DRAIN BRAKE FLUID 
  8. REMOVE AIR CLEANER ASSY 
  9. REMOVE BRAKE MASTER W/PLATE CYLINDER SUB-ASSY (SEE  REPLACEMENT  ) 

    SST 09023-00101

  10. DISCONNECT VACUUM HOSE ASSY (SEE  REPLACEMENT  ) 
  11. REMOVE FRONT BRAKE TUBE NO.5 (SEE  REPLACEMENT  ) 

    SST 09023-00101

  12. REMOVE FRONT DOOR SCUFF PLATE LH (SEE  REPLACEMENT  ) 
  13. REMOVE COWL SIDE TRIM SUB-ASSY LH (SEE  REPLACEMENT  ) 
  14. REMOVE INSTRUMENT SIDE PANEL LH (SEE  REPLACEMENT  ) 
  15. REMOVE INSTRUMENT PANEL FINISH LOWER PANEL LH (SEE  REPLACEMENT  ) 
  16. REMOVE INSTRUMENT PANEL AIR BAG ASSY LOWER NO.1 (SEE  REPLACEMENT  ) 
  17. REMOVE INSTRUMENT CLUSTER FINISH PANEL GARNISH NO.1 (SEE  REPLACEMENT  ) 
  18. REMOVE INSTRUMENT CLUSTER FINISH PANEL GARNISH NO.2 (SEE  REPLACEMENT  ) 
  19. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSY CENTER (SEE  REPLACEMENT  ) 
  20. REMOVE INSTRUMENT CLUSTER FINISH PANEL SUB-ASSY (SEE  REPLACEMENT  ) 
  21. REMOVE COMBINATION METER ASSY (SEE  REPLACEMENT  ) 
  22. REMOVE PUSH ROD PIN (SEE  REPLACEMENT  ) 
  23. REMOVE BRAKE BOOSTER ASSY (SEE  REPLACEMENT  ) 
  24. REMOVE BRAKE BOOSTER GASKET (SEE  REPLACEMENT  ) 
  25. REMOVE INSTRUMENT PANEL JUNCTION BLOCK ASSY (SEE  OVERHAUL  ) 
  26. REMOVE BRAKE PEDAL RETURN SPRING (SEE  REPLACEMENT  ) 
  27. REMOVE BRAKE PEDAL SUPPORT SUB-ASSY 
    1. Disconnect the stop light switch connector and wire harness clamp.
      Fig 1: Removing Brake Pedal Support Sub-Assy
      G02972900Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Remove the 2 bolts and brake pedal support sub-assy.
      Fig 2: Removing Bolts And Brake Pedal Support Sub-Assy
      G02972901Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  28. REMOVE STOP LIGHT SWITCH ASSY 
    1. Turn the stop light switch assy counterclockwise and remove the stop light switch assy.
    2. Remove the stop light switch mounting adjuster.
      Fig 3: Removing Stop Light Switch Mounting Adjuster
      G02972902Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  29. REMOVE BRAKE PEDAL SUB-ASSY 
    1. Remove the nut, bolt, washer and brake pedal sub-assy from the brake pedal support sub-assy.
    2. Remove the 2 brake pedal bushes and collar from the brake pedal sub-assy.
      Fig 4: Removing Brake Pedal Bushes And Collar From Brake Pedal Sub-Assy
      G02972903Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  30. REMOVE BRAKE PEDAL PAD 
  31. INSTALL BRAKE PEDAL PAD 
  32. INSTALL BRAKE PEDAL SUB-ASSY 
    1. Install 2 new brake pedal bushes and the collar to the brake pedal sub-assy.

      HINT:

      Apply lithium soap base glycol grease to the parts indicated by arrows.

      Fig 5: Installing Brake Pedal Bushes And Collar To Brake Pedal Sub-Assy
      G02972904Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Install the brake pedal sub-assy with the bolt, washer and nut.

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

      Fig 6: Installing Brake Pedal Sub-Assy With Bolt, Washer And Nut
      G02972905Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  33. INSTALL STOP LIGHT SWITCH ASSY 
    1. Install the stop light switch mounting adjuster.
    2. Insert the stop light switch assy until the body hits the cushion.
    3. Make a quarter turn clockwise to install the stop light switch assy.
    4. Connect the stop light switch connector.
    NOTE:
    • When inserting the stop light switch assy, support the pedal from behind so that the pedal is not pushed in.
    • The turning torque for installing the stop light switch assy

      Torque: 1.5 N.m (15 kgf.cm, 13 in.lbf) or less

    HINT:

    After adjusting the brake pedal height, adjust the stop light switch assy.

  34. INSTALL BRAKE PEDAL SUPPORT SUB-ASSY 
    1. Temporarily install the brake pedal support sub-assy with the 2 bolts.
    2. Install the brake booster gasket (see REPLACEMENT ).
    3. Install the brake booster assy (see REPLACEMENT ).
    4. Fully tighten the 2 bolts.

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

      Fig 7: Installing Brake Pedal Support Sub-Assy
      G02972906Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  35. INSTALL MASTER CYLINDER PUSH ROD CLEVIS (SEE  REPLACEMENT  ) 
  36. INSTALL PUSH ROD PIN (SEE  REPLACEMENT  ) 
  37. INSTALL BRAKE PEDAL RETURN SPRING (SEE  REPLACEMENT  ) 
  38. INSTALL COMBINATION METER ASSY (SEE  REPLACEMENT  ) 
  39. INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSY (SEE  REPLACEMENT  ) 
  40. INSTALL INSTRUMENT CLUSTER FINISH PANEL SUB-ASSY CENTER (SEE  REPLACEMENT  ) 
  41. INSTALL INSTRUMENT CLUSTER FINISH PANEL GARNISH NO.2 (SEE  REPLACEMENT  ) 
  42. INSTALL INSTRUMENT CLUSTER FINISH PANEL GARNISH NO.1 (SEE  REPLACEMENT  ) 
  43. INSTALL FRONT BRAKE TUBE NO.5 (SEE  REPLACEMENT  ) 

    SST 09023-00101

  44. CONNECT VACUUM HOSE ASSY (SEE  REPLACEMENT  ) 
  45. INSPECT AND ADJUST BRAKE BOOSTER PUSH ROD (SEE  ADJUSTMENT  ) 

    SST 09737-00020

  46. INSTALL BRAKE MASTER W/PLATE CYLINDER SUB-ASSY (SEE  REPLACEMENT  ) 

    SST 09023-00101

  47. FILL RESERVOIR WITH BRAKE FLUID (SEE  BLEEDING  ) 
  48. BLEED MASTER CYLINDER (SEE  BLEEDING  ) 

    SST 09023-00101

  49. BLEED BRAKE LINE (SEE  BLEEDING  ) 
  50. INSTALL AIR CLEANER ASSY 
  51. CHECK FLUID LEVEL IN RESERVOIR (SEE  BLEEDING  ) 
  52. CHECK BRAKE FLUID LEAKAGE 
  53. INSTALL COWL TOP PANEL OUTER (SEE  REPLACEMENT  ) 
  54. INSTALL WINDSHIELD WIPER MOTOR & LINK ASSY (SEE  REPLACEMENT  ) 
  55. INSTALL FR WIPER ARM & BLADE ASSY RH (SEE  REPLACEMENT  ) 
  56. INSTALL FR WIPER ARM & BLADE ASSY LH (SEE  REPLACEMENT  ) 
  57. CHECK AND ADJUST BRAKE PEDAL HEIGHT (SEE  ADJUSTMENT  ) 
  58. CHECK PEDAL FREE PLAY (SEE  ADJUSTMENT  ) 
  59. CHECK PEDAL RESERVE DISTANCE (SEE  ADJUSTMENT  ) 
  60. INSTALL INSTRUMENT PANEL AIR BAG ASSY LOWER NO.1 (SEE  REPLACEMENT  ) 
  61. INSTALL INSTRUMENT PANEL FINISH LOWER PANEL LH (SEE  REPLACEMENT  ) 
  62. INSTALL INSTRUMENT SIDE PANEL LH (SEE  REPLACEMENT  ) 
  63. INSTALL COWL SIDE TRIM SUB-ASSY LH (SEE  REPLACEMENT  ) 
  64. INSTALL FRONT DOOR SCUFF PLATE LH (SEE  REPLACEMENT  ) 
  65. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL 
  66. INSPECT SRS WARNING LIGHT (SEE  DIAGNOSIS SYSTEM  ) 
  67. PERFORM INITIALIZATION (SEE  INITIALIZATION  ) 
    1. Some systems need initialization after reconnecting the negative battery cable.
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