On-Vehicle Inspection

Pedal height from dash panel: 

124.3 - 134.3 mm (4.894 - 5.287 in.) 

If the pedal height is incorrect, adjust it.

1. Disconnect the connector from the stop light switch.
2. Loosen the stop light switch lock nut and remove the stop light switch.
3. Loosen the push rod lock nut.
4. Adjust the pedal height by turning the pedal push rod.
5. Tighten the push rod lock nut.

   Torque: 26 N.m (260 kgf.cm, 20 ft.lbf) 

6. Install the stop light switch.
7. Connect the connector to the stop light switch.
8. Push the brake pedal in 5 - 15 mm (0.20 - 0.59 in.), turn the stop light switch to lock the nut in the position where the stop light goes off.
   Fig 1: Checking Pedal Height

   Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
9. Push the brake pedal in 5 - 15 mm (0.20 - 0.59 in.), check that stop light lights up.
10. After adjusting the pedal height, check the 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. Push in the pedal by hand until the resistance begins to be felt, then measure the distance, as shown.

Pedal free play: 1 - 3 mm (0.04 - 0.12 in.) 

If incorrect, check the stop light switch clearance. If the clearance is OK, then troubleshoot the brake system.

Stop light switch clearance: 

0.5 - 2.4 mm (0.020 - 0.094 in.) 

Fig 2: Checking Pedal Free Play

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

Release the parking brake lever.

With the engine running, depress the pedal and measure the pedal reserve distance, as shown.

Pedal reserve distance from dash panel at 490 N (50 kgf, 110.2 lbf): 

More than 48 mm (1.89 in.) 

If the reserve distance is incorrect, troubleshoot the brake system.

Fig 3: Releasing Parking Brake Lever

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002