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Brake Pedal Sub-ASSY: Replacement

  1. REMOVE METER HOOD SUB-ASSY (SEE  COMBINATION METER ASSY  ) 
  2. REMOVE COMBINATION METER ASSY (see  COMBINATION METER ASSY  ) 
  3. SEPARATE BRAKE MASTER CYLINDER PUSH ROD CLEVIS 
    1. Remove the clip, push rod clevis pin and wave washer, and separate the push rod clevis from the brake pedal.
  4. REMOVE BRAKE PEDAL SUPPORT SUB-ASSY 
    1. Remove the bolt from the brake pedal support sub-assy.
    2. Disconnect the stop lamp switch connector.
      Fig 1: Removing Bolt From Brake Pedal Support Sub-Assy
      G02614141Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Remove the 4 nuts and brake pedal support sub-assy.
    Fig 2: Removing Nuts And Brake Pedal Support Sub-Assy
    G02614142Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE BRAKE PEDAL SUB-ASSY 
    1. Remove the brake pedal shaft and nut from the brake pedal support sub-assy.
    2. Remove the brake pedal sub-assy and 2 bushes.
  6. REMOVE STOP LAMP SWITCH ASSY 
    1. Loosen the stop lamp switch lock nut.
    2. Remove the stop lamp switch assy from the brake pedal support sub-assy.
  7. REMOVE BRAKE PEDAL PAD 
  8. INSTALL BRAKE PEDAL PAD 
  9. INSTALL STOP LAMP SWITCH ASSY 
    1. Install the stop lamp switch assy to the brake pedal sub-assy.
  10. INSTALL BRAKE PEDAL SUB-ASSY 
    1. Apply lithium soap base glycol grease to 2 new bushes.
    2. Install them to the brake pedal sub-assy.
    3. Install the brake pedal sub-assy to the brake pedal support with the nut and brake pedal shaft.

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

    Fig 3: Installing Brake Pedal Sub-Assy To Brake Pedal Support
    G02614143Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. INSTALL BRAKE PEDAL SUPPORT SUB-ASSY 
    1. Install the brake pedal support assy with the 4 nuts.

      Torque: 12.7 N.m (130 kgf.cm, 9 ft.lbf) 

    2. Connect the stop lamp switch connector to the stop lamp switch assy.
      Fig 4: Installing Brake Pedal Support Assy
      G02614144Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    3. Install the bolt to the brake pedal support sub-assy.

      Torque: 24 N.m (240 kgf.cm, 17 ft.lbf) 

      Fig 5: Installing Bolt To Brake Pedal Support Sub-Assy
      G02614145Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  12. INSTALL BRAKE MASTER CYLINDER PUSH ROD CLEVIS 
    1. Apply the lithium soap base glycol grease to the push rod clevis pin.
    2. Install the push rod clevis with the clevis pin, wave washer and clip.
    Fig 6: Installing Push Rod Clevis With Clevis Pin
    G02614146Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  13. INSTALL COMBINATION METER ASSY 
  14. INSTALL METER HOOD SUB-ASSY 
  15. CHECK AND ADJUST BRAKE PEDAL HEIGHT (see  BRAKE PEDAL SUB-ASSY  ) 
  16. CHECK PEDAL FREE PLAY (see  BRAKE PEDAL SUB-ASSY  ) 
  17. CHECK PEDAL RESERVE DISTANCE (SEE  BRAKE PEDAL SUB-ASSY  ) 
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