On-Vehicle Inspection

Pedal height from dash panel: 

142.1 to 152.1 mm (5.594 to 5.988 in.) 

If the pedal height is not as specified, 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 clevis lock nut.
4. Adjust the pedal height by turning the pedal push rod.
5. Tighten the clevis lock nut.

   Torque: 26 N.m (265 kgf.cm, 19 ft.lbf) 

6. Install the stop light switch.
7. Connect the connector to the stop light switch.
8. Push the brake pedal in 5 to 15 mm (0.20 to 0.59 in.) and turn the stop light switch to lock the nut in the position where the stop light turns off.
9. Push the brake pedal 5 to 15 mm (0.20 to 0.59 in.), and check that the stop light lights up.
10. After adjusting the pedal height, check the pedal free play.

Fig 1: Adjusting Pedal Height

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002

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 until the beginning of the resistance is felt. Measure the distance, as shown.

Pedal free play: 1 to 6 mm (0.04 to 0.24 in.) 

If the result is not as specified, check the stop light switch clearance.

If the clearance is OK, then troubleshoot the brake system.

Stop light 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

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 85 mm (3.35 in.) 

If the result is not as specified, troubleshoot the brake system.

Fig 3: Checking Pedal Reserve Distance

Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002