Brake Pedal Sub-ASSY: Adjustment

CHECK AND ADJUST BRAKE PEDAL HEIGHT
1. Inspect brake pedal height.
  Pedal height from asphalt sheet:
  
  M/T: 134.9 to 144.9 mm (5.311 to 5.703 in.)
  
  A/T: 136.0 to 146.0 mm (5.353 to 5.747 in.)
2. Adjust brake pedal height.
  1. Disconnect the connector from the stop lamp switch assy.
  2. Remove the stop lamp switch assy.
  3. Loosen the clevis lock nut.
  4. Adjust the pedal height by turning the push rod.
  5. Tighten the clevis lock nut.
    Torque: 26 N.m (265 kgf.cm, 19 ft.lbf)
  6. Install the stop lamp switch assy.
  7. Connect the connector to the stop lamp switch assy.
  8. Push the brake pedal in 5 to 15 mm (0.20 to 0.59 in.), and turn the stop lamp switch assy to lock the nut in the position where the stop lamp goes off.
  9. After installation, push the brake pedal in 5 to 15 mm (0.20 to 0.59 in.), check that stop lamp comes on.
Fig 1: Inspecting Brake Pedal Height
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
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 resistance is felt. Measure the distance as shown in the illustration.
  Pedal freeplay: 1.0 to 6.0 mm (0.039 to 0.236 in.)
  
  If incorrect, proceed to the following step.
  1. Check the stop lamp switch clearance.
    Stop lamp switch clearance:
    
    0.5 to 2.4 mm (0.020 to 0.094 in.)
  Fig 2: Checking Pedal Free Play
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
If the clearance is OK, troubleshoot the brake system.

If incorrect, adjust the stop lamp 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 in the illustration.
  Pedal reserve distance from asphalt sheet at 294 N (30 kgf, 66 lbf):
  
  w/o ABS: 78 mm (3.07 in.) or more.
  
  w/ ABS: 76 mm (2.99 in.) or more.
  
  w/ VSC: 76 mm (2.99 in.) or more.
  
  If incorrect, troubleshoot the brake system.
Fig 3: Checking Pedal Reserve Distance
Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002